SHOP MANUAL
V65 MAGNA-VF11 DOC

HOW TO USE THIS MANUAL

GENERAL INFORMATION

Follow the Maintenance Schedule (Section 3}
recommendations to ensure that the vehicle is
in peak operating condition and the emission
levels are within the standards set by the U.S.
Environmental Protection Agency and California Air Resources Board. Performing
the first scheduled maintenance is very
important. It compensates for the initial wear
that occurs during the break-in period.

LUBRICATION
MAINTENANCE
FUEL SYSTEM
ENGINE REMOVAL/INSTALLATION
COOLING SYSTEM
CLUTCH SYSTEM

Sections 1 through 3 apply to the wh.ole
motorcycle, while sections 4 through 21
describe parts of the motorcycle, grouped
according to location.

GEARSHIFT LINKAGE
L&J

z

(!)

zw

Find the section you want on this page, then
turn to the table of contents on page 1 of that
section.

ALTERNATOR
CYLINDER HEAD/VALVE
CRANKCASE

Most sections start with an assembly or
system illustration, service information and
troubleshooting for the section. The subsequent pages give detailed procedures.

PISTON/CRANKSHAFT
TRANSMISSION

If you are not familiar with this motorcycle,
read the TECHNICAL FEATURES in section

DRIVE TRAIN

23.

FRONT WHEEL/SUSPENSION

If you don't know the source of the trouble,
go to section 24, TROUBLESHOOTING.

REAR WHEEL/SUSPENSION
HYDRAULIC BRAKES

ALL INFORMATION, ILLUSTRATIONS, Dl·
RECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON
THE LATEST PRODUCT INFORMATION
AVAILABLE AT THE TIME OF APPROVAL
FOR PRINTING. HONDA MOTOR CO.,
LTD. RESERVES THE RIGHT TO MAKE
CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY
OBLIGATION WHATEVER.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED WITHOUT WRITTEN PER·
MISSION.

...J

~

BATTERY/CHARGING SYSTEM

<2:

a:

IGNITION SYSTEM

1(.)
L&J

ELECTRIC STARTER

...J

w

SWITCHES
WIRING DIAGRAM
TECHNICAL FEATURES
TROUBLESHOOTING

HONDA MOTOR CO., L TO.
SERVICE PUBLICATIONS OFFICE

Date of Issue: Nov., 1985
© HONDA MOTOR CO., LTO.

---- ···

· ·--· IMPORTANT SAFETY NOTICE--

lndica1es a s/rong possibilify

.

CA UTION. lndh:at es u f}f JS.~ihl
ty

o{.~f'FN

·

·

-·

personu/ injury or loss o{ li[e i[ ins/ructions nre nor followed.

u.f' personal injury or f.'(/ Uifllllt'IIT damage if instruct io11s arc not j(Jiloll'ed.

NOTE: Gives helpfu l information .
Or. tailed descriptions of standa rd work shop procedures, safety principles and service ope ratio ns arc not included. It is
importan t to note t hat this manual contilins some w arnings <Jnd cautions against some specific service methods which
cou ld cause PER SONA L INJURY to service personnel or cotlfd clam~Je
a vehicle or render ir unsafe . Ple ase understand
thi..tl those warnings could not cover all conceiv able ways in which service, whether or not recomrnendet.l by Honda might
l)e done or of the possibly ha.lan.Jou s consequences of ~<J C h eonccivable way , nor could Hond a inves tigate all such ways.
Anyone using service procedures or tools. whether or no t recommended by Honcli.l must satisfy /Jimself thoroughly tha t
nei ther personal safety nor vehicle safHty will be jeoJ.)ard itcd by the service me thods or tools selected .

1. GENERAL INFORMATION
~

~ENRAL

-------

Ill

1-1

SAFETY

SERVICE RULES

1- 1

MODEL IDENTIFICATION

1-2

SPECIFICATIONS

1-3

TORQUE VALUES

1-5

TOOLS

1-7

CABLE & HARNESS ROUTING

1-9

EMISSION CONTROL SYSTEM

1- 17
-

...... ·- ·----·

GENERAL SAFETY
IM·Wi@J

t?d-M!Jml

If the engine must be running to do some work, make sure
the art'a is Wt'/I·Vt'ntilated. Never run the engine in a closed
area. The exluJust contains poisonous carbon monoxidt'
gas.

The batrery electroly te contains sulfuric acid. Protect your
eyes, skin , and clothinx. Jn case of contacr, flush thorough·
~v
with water and call a tloctor ij' elaro~vt
gns in _vour

t:res.

l '?ttt.l;W@i

1£1-Wi@l

Gasoline is extremt>ly flammable and is explolive under
certain conditions. Do not Jmoke or allow flames or sparks
in your working area.

The bouery generates hydrogen gas which can be highly
explosive. Do not smoke or allow flames or sparks near the
barury, especia/ly while charging it.

SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA's
design specifications may damage the motorcycle.
2 . Use the special tools designed for this product.
3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners . The use of incorrect tools and fasteners may damage the motorcycle.
4 . Install new gaskets, 0 -rings, cotter pins, lock plates, etc. when reassembli ng.
5. When t ighte ning bolts o r nuts, begin with large r-diameter or in ner bolts f irst, and tighten to the specif ied to rque diagonally,
u nless a part icular sequence is specified.
6. Clean parts in cleaning solvent upon d isassembly. Lubricate any sliding surfaces before reassembly.

7. Aftu feassembly , check all paru for pfoper installation and operation.
8. Ro ute all e lec trical wires as shown on pages 1-9 th ro ugh 1·16 Cable and Ha rness Ro uting.

1-1

MODEL IDENTIFICATION

BEG INNIN G F N O. SC 120- DM000029
E NO. SC12E - 2000039

The color label is attached t o the f rame behind the left side
cover.

The fr ame serial number is stam ped on th e steering head
right side.

The veh icle identification number (VIN) is on the stee ri ng
head left side.

serial number is stamped on top of the right

The carburetor identificatio n number is on t he carburetor
body left side.

c:ra nkcase .

1-2

GENERAL INFORMATION

SPECIFICATIONS

· ···-·
· -~

-=
'83. .f~:rA
:~ : I
'84. '85 I

ITEM
Overall length
Overall width
Overall h eight

'83, After '85 :
'84, '85:

SPEC IF ICAT IONS

- -- -- -

2,280 mm (89.8 in)
810 mm (31 .9 in)
825 mm (32.5 ini
1,210 mm (47 .6 inl
1,230 mm (-18.'1 in)
1,5~
mm (62.8 in)
800 mm (31 .5 in i
350 mm ( 13.8 in)
155 mm ( 6.1 in)
245 kg (540 !b)
265 kg (584 lh)

!

Wheelbase
Scat height
Foot l)l!Q hl.'iyht
Ground c learance
Dry weight
Curb weight

- - --

Type
Fron t suspension, travel
Rear suspension, travel

'83:
After '83 :

Gross vehic le weigh t rati ng
Vehicle load capacity
Front tire size
Rear t ire size
Cold t ire

U p t o 90 kg
{200 lbs) load

Up to vehic le
Front
capacit y load
Rear
·····--- - -·-·-·-- ··---· .
Front brake, lining swept area
Rear brake, lining swep t area
Fuel capac ity
Fuel reserve capacity
Caster angle
T rail
Front for k oil capaci t y
Type
Cylinder arr angement
Bore and stroke
Displacement
Compress•on ra ti o
Valve tra;n
Maximum hor5enower
Maximum torQue
Oil capacity
Coolant capacity
Lubrication SY$tem

Air f il tr<Jtion
Cy Iin der comprc ssio n
Intake valve
Opens
Closes
Exhaust valve
Opens
Closes
Valve clearance (Cold)
Engine we ight
Idle speen

32 psi (225 k Pa. 2 .25 kg/em : )
32 psi ! 225 k Pa. 2.25 k g /e m~
}

Front
Rear

pressures

ENG INE

Double cradle
Telescopic fork . 160 mm (6.3 in)
Swingarm/Shuck absorber. 11 2 .nrn (4.4 in)
Swinqarm/Siwck absorber . 11 5 rnm (4.5 in)
435 kg (960 l h)
168 kg (370 lb)
Ml10/90· 18 Tubeless
M 140/ 90·16 T ubeless

------1

32 psi 1225 k Pa, 2.25 kg e/ m ~)
40 ps; 1280 kPa, 2.80 kg/ em' 1
_ _ __D_o_u-ble-disc, 904
~;:-~· {'i·40.1 sq ini
Sin~le

disc. 516 cm 2 (80 sQ in)
17 liters !4.5 US gal, 3.7 Imp qal)
3 liters (0.8 U S gal, 0 .7 Imp gall

59.' 40'
105 mm (4 . 1 inl
R : 565 cc (1 9.1 o zl. L : 580 cc ( 19 .6 o7 )
Water coolr.d 4 st rok e, DOHC engine
4 cylinders, 90"V
79.5 x 55 .3 mrn 13 . 13 x 2.18 in)
1,098cm 3 (67 cu ·in)

10.5: 1

'83. '84, '85 :
After '85 :

Si lfmt, m tJiti ·l.nk chilin drive and DOHC with rocker arms
116.0 BHPi 9,500 rpm
9.7 kg·m (70.1 ft·lb)/7,500 rpm
3.5 liters {3 7 US qt, 3.1 Imp qt) after dtsassernbly
3.0 liters (3 .2 US Qt , 2.6 Imp Qt) after d raining
3 .45 l iters (3.6 5 US Qt . 3.04 Im p qt )
3.20 li ters (3.38 US Qt. 2.81 Im p qt i
Forced pressure and wet sump
Paper fil tl!r
13 + 2 kgicm ; (184 .:. 28 psi)

8-. !8TDC)
40~

(ABDC)
at 1 m m lift
43c !BBDCI
7''(ATDC)
IN/ EX: 0 .15 mm (0.006 in)
96 .7 kg (213.2 ll>)
1,000 l 100 r pm

1-3

GEN ERAL INFORMATI ON

TORQUE VALUES

• ENGIN E

-r-

. ' ..
Item

·-

- - -··

Cylinder head cover
Cy lindflr hP.<=~n

Flywheel bolt
Clutch center
Crankcase

Thread Dia. (mml

8

6

16
8
16

6

8
10
12
25
10
8
6
22
7
8
7
12
20
8
8
64
30
7
12
8
6
12

14

3
14
Rocker arm shaft
Cam sprocket
Starter clutch
Shift fork cente r
Camshaft chain guide A
Oi l f i lter
Out put gear case
Output gear case bearing holder
Output gear case bearing (outer)
(inner)
Valve adjustment nuts
Drain bolt
Connecting rod nuts
Drum stopp er pivot shaft
Prim ary d rive gear
Oil pressure swi tch
Pin ion beari ng ret ainer
Pin ion nut
Gear case cover bolt

8
8

4
4
1
1
16
1
8

16
10

1

2
6

Final gear case attach ing nu t

.....

O'ty

L_.3

··T"" - - -

Remarks

Torque N-m (kg·m, ft-lbl

8- 12
10- 14
21 --25
48- 52
80

~·

10

0

63- 67
43- 47
2 1- 25
10- 14
45- 50
18- 20
26 - 30
16 - 20
21 - 25
15- 20
2 1- 25
30- 34
90- 110
70- 80
2 1- 25
35- 40
30 --34
8- 12
80 -1 00
10 - 14
100- 120
100- 120
35- 45

8

23- 28

10

45- 70

(0.8-1.2, 5.8-9.0)
(1 .0-1.4, 7-10)
(2.1 -2.5, 15-18)
(4.8-5.2, 35-38)
(8 .0- ·10.0, 58-72)
(6.3-6. 7' 46-48)
(4 .3-4.7, 31-34 )
UBS
(2 1-2.5, 15-18)
(1.0-1.4, 7-10)
· - Apply LOC
TIE
(~)
(4.5-5.0, 33-36)
'""- 2 71 to the threads
(1.8-2.0. 13-14)
(2.6 -3.0, 19-22)
(1.6--2.0, 12-14 )
(2.1-2 .5,1 5-18)
(1.5-2.0, 11-1 4)
12. 1-2.5, 15-18)
Socket bolts.
(3.0-3.4, 22-25)
(9.0-11.0, 65- 80)
(7.0-8.0, 51-58)
(2. 1-2. 5, 15-18)
- Apply oil to t he
(3.5-4.0, 25-29)
thread and seating
surface
(3.0-3.4, 22-25 )
(0 .8-1.2, 5.8-9.0)
(8.0-10.0. 58-72 1 '
Apply "alan I to th•
(1.0- 14, 7-10)
t hreads
(10.0- 12 0, 72-87)
(10.0-12.0, 72-87)
(3.5-4.5, 25--33)
(2.3-2.8. 17-·20)
(4.5-·7.0, 33-·51 J

·l

r

.J

---··- ·-- -·· . -···

• CHASSIS

..-- ·

.J

__?~ ~ Y .. ~ h r e~d

Item

Sub-f rame bolts

(U pper)

(Lower) :
Shock absorber mount bolts/ nuts
!Upper)
(Lower)
Handlebar upper holder
Rear brake pedal
Change arm
Side stand
Engine hanger bolts

2
2

2
2

;
.

l b) - - - t - - -_R_e_m_a_rk_s_
_ D __ia_._(_m_m_l-+- -Torque
- --N -m
-(kg·m
- -. ft·
--

10
10

60-70
35-·45

(6.0-7.0, 43-51 )
(3.5-4.5, 25-33)

8

40- 50
30 --40
40- 50
24 - 30
10- 15
35- 45
20- 30
35-45

(4.0-5.0, 29-36)
(3.0-4.0 . 22-29)
(4.0-5.0, 29-36)
(2.4-3 .0, 17-22)
(1 .0-1 .5, 7-11 )

10

4

8
8
6

1

10

2

8
10

4

_

-1

(3.5·-4 .5: 25-JJ )

(2.0-3 .0, 14-221
(3.5-4.5, 25-33)

1-5

GENERA L INFORMAT ION

- ---·-

.. -···
O 'ty

Item

-

~

·-·- .. ··- ·-·-·--- -- --+Brake hose bolts
'83, '84. '85 : ' 7
*7
Afte r '85:

10
. 10
7
6

6
8
8
4
4
4
4
30
10

8
30
30
30
10
24

24
7
10
8
12
8
18
18
8

8
8

'

I

j.· 1- - ~

8
8

.

I

..

--- --,

Remarks

Torque N-m (kg-m, ft·lb)
.........
·- -·
25-35 (2 .5-3.5, 18- 25)
37-43 (3 .7- 4.3, 27-3 1)
4-7
(0.4 - 0. 7, 2.9-5.1)
10-14 (1.0- 1.4, 7-10)
10-14 (1.0- 1.4, 7-10)
20-30 (2 .0- 3.0, 14 22)
18-28 ( 1.8-2.8, 13-20)
2-3 .5 (0.2- 0.35, 1.4-2.5)
1-2
(0.1- 0.2. 0 .7- 1.4)
2-3.5 (0.2- 0 .35, 1.4 -2.5)
1-2
(0. 1- 0.2, 0.7 - 1.4)
10-14 (1.0- 1.4, 7-10)
30-45 (3 .0 - 4.5, 22-33)
18-25 (1 .8- 2.5, 13-1 8)
90-120 (9.0- 12 .0. 65-87)
16-20 (1.6-2.0. 12-14 )
100- 130 (10.0 - 13.0, 72-94)
45-70 (4 .5- 7.0, 33 -51 )
80-120 (8.0 - 12.0, 58-87)
90-120 (9.0 - ·12.0, 65-87)
9-13 (0.9- 1.3, 7-9}
45--55 (4 .5- 5.5, 33-40)
18-30 (1.8- 3.0, 13-22)
55-65 (5.5- 6 .5, 40-47)
18-30 (1 .8-3.0. 13-22)
85-105 (8.5- 10.5, 61-76)
80-100 (80- 10.0. 58-72)
18--25 (1.8- 2.5, 13-18)
27-35 (2.7-- 3 .5, 20-25)
25-30 (2.5- 3.0, 18-22)
15-·25 (1 .5- 2.5, 11-18)
15-25 (1 .5- 2.5, 11-18)

- -- -···

I

........ _

····------··

Thread Dia. (mm)

Caliper a ir bleed bolt
3
Brake master cyli nder holder
4
Clutch master cylinder holder
2
Axle pinch bolt
1
Front fork stabilizer
4
Brake master cylinder cap
'83: 1 2
After '83: · 2
Clutch master cylinder cap
' 83: : 2
After '83: iI
2
Fin al gear oil filler cap
1
Front caliper
4
Rear brake torque rod
2
Swingarm left pivot bolt
Swingarm right pivot bolt
Swingarm p ivot lock nu t
1
Final gear case nut
3
Steering stem nut
'83. '84. '85: .
After '85: 1 * 1
Front fork top pinch bolt
2
Front fork bottom p inch bolts
2
Steering stem pinch bolt
Front axle
Front axle pinch bolt
Rear axle
'83, '84. '85:
After '85 : ~ 1
Gearshift pedal pivot
Fuel reserve sensor
1
Handlebar pinch bolt
2
Front fork socket bolt
2
Fork tub.! cap
2
Steering bearing adjustment nut
'83 :
After '83:
Brake disc
·s3. '84 . ·s5: 1s
- - - -·After '85:

.

-·· ·---····

14-16 (1.4- 1.6, 10-12)
19-23 (1.9- 2.3, 14-17)
25-30 (2.5- 3.0. 18-22)
37-43 (3.7- 4 .3, 27-3 11

!

·- - ---'

·· ··-· --

Torque specifications listed above are f or important fasteners. Others should be tightened to standard torque values listed
below.

• STANDARD TORQUE VALUES

I
I ..

5mm•::aod.n01 ...

6 mm bolt and nut

~

,

, ,

____ _, _

Torque Values
N·m (kg-m, ftlb}
,
,

_____ ___

,r
~-

4-6 (0.4-0.6, 3- 4)

-- -

Torq ue Values
N-m (kg-m, ft-lb)

Item
-

,

8-12 (0.8-1.2, 6 - 9)
18-25 (1.8-2.5, 13-18)

10 mm bolt and nut

30-40 (3.0- 4 .0, 22-29)

8 mm flan ge bolt and nut

12 mm bolt and nut

1 50-60 (5.0-6.0. 36-43)

10 mm t lange bolt and nu t

1-6

6

ITIIII

- · - --

,

3-5 (0.3- 0.5, 2-4)

8 mm bolt and nu t

. - -... . . . ._. . . _,. ___ l_ ·-----........_ ,.....________ ,_,

__ __ ---

5 mm sc rew
6 mm screw
flange bolt and nut

6 mm SH flange bolt
- --'--

7-11 (0.7- 1.1, 5-6)
10-14 ( 1.0- 1.4, 7 10)
20-30 (2.0-3.0, 14-22)
30-40 (3.0- 4.0, 22-29)
7.5-10.5 (0.75-1.05, 5.4-7 .6)
-

-

·-----..

.-

- -·-

- --

GENERAL I NFORMATION

TOOLS
• SPECIAL

,--- ·

DESCR IPTION

Lock nut wrench , 42/56 mm
Drive shoft

d i~/

~e

mhly

rnol

N ~

AL TER NATIV E

_N_U_M_B
_E_R
__

-+_

079 16· MB40000

R_EF~

SECT.l
13

07 9G4 MBII0 100

14

Valve guide d river artachment

07943-M840000

10

Vucvum gauge se1

0 7404-0030000

• Vacuum gauge set

Oil pressure gAuge

0 7506-3000000

h.EQuiva

Oil pressure gauge attachm ent

07510·-4220100

lu r ~t tools commercially
avarlable on U.S.A.
~j

M937B-021 -

XXXXX

3
2

2

Compression gauge attachment

07510 · MB00101

3

Carburetor pilot screw wrench

07908-42 20201

3

Swingarm lock nut wrench

07908 - 4690001

Valve adjusting wrench

07908-MB00\00

lock nut w rench

KS - HB A -08 -·
469 (U.S.A. only)

k

16

3

Retainer wrench

079 10 - 4630100

Snap ring pl iers

0791 4 - 3230001

Steerin g st em socket

07916 - 3710100

Lock nut wrench

07916 - 4220000

7

Loc k nut wrench, 30/64 mm

07916 - MBOOOOO

13

6 mm hex. wrench

07917 - 3230000

Shaft holder

07923 - 6890101

Final pinion holder

07926- ME90000

Shaft pull er

0793 1- ME40000

Bearin(l rOCP. insert auachmenl

0793 1-4630300

Bel!rin g remover handl e

07936 - 37 10 100

Bearing remover weigh t

07936- 3710200

14

EquivCIIent t ool commerciall y
avaiable in U .S.A .

j

7. 15, 17
15

-Equivalent tool commerci ally

j-i. available in U .S.A.

15
13
14

Pino

~

puller set

07935- MBOOOOO

14

01

Pini on puller and
Pinion pi.J II P.r attachment kit

07931-4630200
07931 - MBUOOOO
14
13

Bearing remover set

07936 ·-·3 71 0000

13

Beari ng remover, 17 mm

07936 - 3710300

13

Bearing puller & driver anachment

07934 ····MBOOOOO

14

Bearing remover shaft

07936 - 8890100

16

Bearing remover head

07936 - -8890200

16

Driver

07949 - 3710001

Valve guide driver

07942 - 3290100

Socl<et bit. 1 7 mm

07703-0020500

Ball race & bearing driver attachment

07945 - 3330300

Ball race remover

07946- 3 71 0500

Ball race driver

07946-3710701

Steerin g stem dri ver

07946 -- MBOOOOO

Fork seal drover

07947 KA50100

Fork seal driver anachment

0 794 7 - ·KFOOl 00

Rl!ce remover attachment

07953- MJl OOOA

Drive shaft dis/assembly tool (C)

07964 ··MB00300

14

Re<Jr shock absorber compressor
<ltt<lchment

07967- KCl 0000

16

I

07949 - 3 710000

Driver

l,Equivalcnt tool co mmercially
~avilb
e in U .S.A.

11. 15
10
16
14

I

15

I

15

r Attachment "B" collar
L

Steering st em driver

07964-MB00200
07946-3710601

15
15
15

{U.S.A. only)

15

Valve guide reamer. 5.5 mm

07984-2000000

10

Flywh ee l cover

07998 - M 800000

3

A ttachment

07946 - 3710200

11
Vacuum pump

!> 1- A H- 260- MC7

IU.S.A. on ly)
ST -··AH-· 255- MC7

Pressure pump
Camshah lifter

07979 MK30000

· ·- · ---· __r:~

·~ ~ ·)

3

1-7

GENERAL INFORMATION

,. .
l

• COMMON

~ l ~t ~ · ~:

R I P T I ON

·~- :T-~

A djusting w rench (A )

I ~708

Lo<:k nut wren ch, 30 x 32 mm

·

4: ~: ::0 .
-03

A LTERNAT IVE

0

EQu ivalent tool s commerco ally
avaolable in U.S.A

0 7716-·0020400

;·--N

UI:B~

·R

II
;

- ~EF
!

Extension bar

07716-0020500

Universal holder

07 725-0030000

Flywheel holder

07725- 0 040000

Rotor p uller

07733-0020001

Rot or puller

07933- 3290001
(U .S.A . only)

.

. SECT.

-<

~5

15
7,9

9

32 x 35 mm

07746 -001 0100

14

Attachment, 37 x 40 m m

07746-0010200

Attachment, 42 x 47 mm

07746-{)01 0300

14, 16
7,1 3,14, 15. 16

Attachment, 52 x 55 mm

07746-0010400

13, 14, 16

x 68 mm

0 7746-0010600

13

Polot, 15 mm

07746 - 0040300

15

Pilot, 17 m m

07746-{)040400

13

Pi lot, 20 mm

07746-0040500

16

Pi lot. 30 mm

07746-0040700

13, 14

35 mm

07746-0040800

A ttachmen t.

Attachment, 62

Pilot,

Driver

07 749-{)01 0000

Drive r

07742-.0030100

Attachment, 25 mm

0774 2 -0030200

Ati.achment, 30 mm

07746-0030300
0 7746-{)0501 00

Bearin g remover shaft

7, 13
Driver

07949--611 0000

Q·Driver

07945- 3 710200

)3. 14

14
13
15, 16

Bearing remo ver h ead, 15 mm

07746-0050400

Bearing removor head, 20 mm

07 746-{)050600

I

16

Valve spring compressor

07757-0010000

Rear shock absorber ccmprenor

07959-3290001

j_ __

10
14, 16

1-8

15

GENERAL INFORMATION

CABLE & HARNESS ROUTING

0

Note the following when routing cables and wire

harnesses.
A loose wire, harness or cable can be a safety hazard.
After clamping, check each wire to be sure it is
secure.
•

X
·-~

Do not squeeze wires against the weld or end of
its clamp.

• Secure wires and wire harnesses to the frame
with their respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
•

Route harnesses so they are not pulled taut or
have excessive slack.

•

Protect wires and harnesses with electrical tape
or rubing if they contact a sharp edge or corner.
Clean surfaces thoroughly before applying tape.

•

Do not use wires or harnesses with a broken
insulator. Repair by wrapping them with pro·
tective tape or replace them.

•

Route wire harnesses to avoid sharp edges or
corners.

•

Avoid the projected ends of bolts and screws.

•

Keep wire harnesses away from the exhaust pipes
and other hot parts.

•

Be sure grommets are seated in their grooves
properly.

•

After clamping, check each harness to be certain
that it does not interfer with any moving or
sliding parts.

~

0

X
~

• After routing, check that the wire harnesses arc
not twisted or kinked.
•

Wire harnesses routed along the handlebars
should not be pulled taut. have excessive slack,
be pinched, or interfere with adjacent or sur·
rounding parts in any steering position.

1-9

GENERAL INFORMATION
'83, '84, '85:

CLAMPS

'83, '84, '85 :

CHOKE CABLE

.......
EQUALIZER PIPE

'83, '84. '85:
FRONT BRAKE HOSE

CLUTCH HOSE

'83, '84. '85;
M ETER

METER

---r--------,
----4·,
\'; I

I

<... ______ _) / )
•'
· ,. . _ _ • •- · · · " " '

•

·····•'"

I

,

~-

.\

I

I

......,

i

\\ \\ .J

\

\

\

;

I

FUSE
BOX

'

\\
\\
IGNITION SWITCH

1-10

TURN SIGNAL

GENERAL INFORMATION

'83, '84, '85:

-·~

.··.
.... :~.

-:. -.

-

.........

~- ..
•
'~-

CLAMP

_,_.--------

··"\

..·.

'·-i;
ALTERNATOR WIRE

'83, '84, '85:

BATTERY CABLE
OIL PRESSURE SWITCH

GENERATOR

STARTER MOTOR
WIRE

1-11

GENERAL INFORMATION

'83, '84, '85:
THROTTLE CABLES

MAIN HARNESS
COOLANT RESERVE TANK
OVERFLOW TUBE

COO LING FAN
MOTOR WIRE

/ / ( )f;ADIATOR OVERFLOW TUBE '-....

£ ~/!;

·-...._f i ! !
! i! /...

\ ~f

, 11:

'\ \,

THERMOSTAT IC SWITCH

'83:

FUEL PUMP

1-12

-'1

I
"! I

FUEL HOSE

(

\\

FUEL RESE RVE SENSOR

GENERAL INFORMATION
After '83:

FUEL PUMP

After '85:

THROTTLE CABLES
WIRE BANDS

/

CHOKE CABLE

1-13

GENERAL INFORMATION

After '85 :

After '85:

M ETER

FRON T BRAKE HOSE
CLUTCH HOSE

./·---·-...
•• ••,.,

I

.

;

.·•

.....
_

I

'

' .) ...-

.·

. ·. I -· -..ii.
• .

I

.

,-·
i!

. . {" -

.

·. I

..........

··-- --!
SPEEDMETER CABLE

\

I

.. ·· j

!
I

ENGINE
STOP

TURN SIGNA L
CANCEL UNIT

IGN ITION SWITCH
After '85:

THROTTLE
CABLES

COOLAN T RESERVE TANK
OVERFLOW T U BE

~-·

, ____

' -\
THEMOSTATIC SWITCH

1-14

-

~

FU EL RESERVE
SE NSOR

GENERAL INFORMATION

After '85:

-

~-

...

-:::-: -:-·

<.::.<.'.

·· ... -·

CLAMP

_____ ..----·-~-

.\.

··.·.-·.··-.. \,

-

I.HANGF SWITCH WIRE
...'

-::.··.

"··

.. _.

---,

'

CLAMPS

\,ALTERNATOR WIRE
..

After '85:

---------

BATTERY BREATHER TUBE

AL TE RNA TOR Wl RE

OIL PRESSURE
SWITCH

'""'

.""' \j

.. -~,

STARTER _

RELAY

____.,'\._.-~

\\

~-GENRATO

PULSE

·"'

WIRE

STARTER MOTOR
WIRE

1-15

GENERAL INFORMATION
After '85 (California model)

AIR VENT CONTROL VALVE
iAVCV)

AIR VENT CONTROL VALVE
(AVCV)

L
......

CANISTER

1-16

......

·-........

GENERAL INFORMATION

EMISSION CONTROL SYSTEM
The U.S. Environ mental Protection Agency anti California Air Resources Board (CARB) require manufactu rers to certify
tt1at th eir motorc ycles comply with anr licable exhaust emission st andards during their us eful life, w hen operated and
maintai ned according to the instructions provided, and that motorcyc les bu ilt a fter J<lnu<lry 1, 1983 comply with applicable
noise ~)mison
standards for one year or 6,000 km (3.730 miles) after the time of sale to th e ultimate purchaser, when
op€rate<l and maintained accordi ng to th e in str uctions prov ided. Compliance with the terms of the Distribu tor's Warranties
for Honda Moto rcycle Em1ss1on Control ~yst1
1 1TS
is necessary in order to kel:! p the emission warranty in effect.

SOURCE OF EM ISSIONS
Th e combust io n process produces carb on monoxide and h ydrocarbons. Control of hydrocarbo ns is ve ry important b ecause,
u nder certa in cond itions, they react to form photochemical smog when subjected to su n light. Carbon mo noxide does not
react in th e setm e way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other syst ems. to reduce carbon m o noxide and hydrocarbons.

EXHAU ST EMISSION CONTROL SYSTEM
Tile e xh <lLl St emission control sy stP.m is compose(! of lean carburet or sl~ti
idl1~
spe~d
adjustment with the throttle sto p screw.

i!-J

S,

und no adjustments should be made f~xcept

CRANKCASE EMISSION CONTROL SYSTEM
The V65 engine is equ ipped with a crankcase emission contro l system wh ich routes crankcase em issions through the ai r
cleaner and into the combust ion chamber. Condensed crankcase vapors are accumulated in a storage tank wh ich must be
emptied p eriodically See the Maintenance Schedule in Section 3 .

AIR CLEANER

~:FRESH

AIR
4- :

BLOW-BY GAS

1 .. 17

GENERAL INFORMATION
EVAPORAT IVE EMISSION CONTROL SYSTE M ('84 Cali fornia model)
This model complies with California Air Resou rces Board requi rements fo r evaporative emission regu lations.
Fuel vapor from the fuel tank is routed into a churco<JI c<Jnister where it is absorbed and stored whi le the engine is stopped.
\l\/hcn the motorcycle is running and the purge control diaphra!Jm valve is open. fuel vapor in t he charcoal canister is drawn
engine through the carburetor.
into thl~

After '85 :
Th is model comnlies with California Air Resources Board evaporative em ission requ irements. Fuel vapor from the fuel tank
and carburetor is d irected into Lhe t:harcoal canister where it is absorbed and stored while the engine is stopped. When the
engine is runni ng and the purge control diaph ragm valve is open. fue l va por in the charcoal canister is drawn into the engine
through the carburetor.

PURGE CONTROL
VALVE

~

..0.

l .,_·~
-L~1·
rt" "'~TON

J _j.

TO

L ~-·

ATMOSPHERE

1I - 1~._ - ~

TO EACH
.
CARBU RE TO R .

'~:._

'·

'I

LI NOER

l

-

'

1

.,

,._/ )1- .

~ ~;

')i:., ·, , .
,.
......

1

I

·/',

It

/ . : ~ ~ 1 -.I
1.1

~

.<=:J FRESH AIR

c

I

l,

\

D~IN

CHARCOAL
CANISTER

~\

l•...__ ./.

/

-.-----

o..J

P.C. PORT

1-18

FUEL TANK

"'-ilj . - - ,~

O 3l~

~ ··.,:i..._.
:>.
Ill. 1 ~ ~ - I

/f' j ')(~:
·F•t •!,'/

~Y

_

.

': "

~'"-

SEPARATOR
_/

--1 {f ,._~"-

·-·

" ''-..

I.

[-.. ,i

GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: F!!d!!ral I<Jw prohibits the following acts or the
causing thereof: (1) The removal or rendering inoperative by any person, other than tor purroscs of maint~ce,
repair, or
rE!placement, of any device or element of design incorporated into any new vehiciP. for the purpose of nois+! control prior to its
sale or delivery to the ultimatl! purchaser or while it is in use; or (2) the u~e
of the vehicle after such <levice or elemem of
design has been removed or rendered inoperatv~
by any person.
AMONG THOSE ACTS PHtSUMI:lJ IU CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust guscs.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system. with parts oth!!r than thos1! specified
by the manufacturer.

EMISSION CONTROL INFORMATION
LABEL
An Em iss ion Control Information Label is located
on the frame as shown. It gives basic tune-up
specifications.

f

EMISSION CONTROL
INFORMATION LABEL

VACUUM HOSE ROUTING DIAGRAM
LABEL (California model only)
The Vacuum Hose Rounting Diagram Label is
on the frame behind the left side cover. Route the
vacuum hoses as shown on this label.

'84, '85:

After '85:

.,

VhC,JUM HOSf. ROUTING OIAGRAM

·!

Ll'o:,;ll\1( ·.:.MIL••

:.0·•*.1:1'1.·••.:.1:·•

F•;J.;>()I:.AIIYr o 4J,hl.

.,

.·

lllotf;

. .-:.
VACUUM HOSE ROUTING DIAGRAM LABEL

1-19

LUBRICATION

COUN TERSHAFT

2-0

2. LUBRICATION.,
~-SERVIC

INFORMATION

2-1
2-2
2-3
2-3
2-4

TROUBLESHOOTING
ENGINE OIL LEVEL
ENGINE OIL & FILTER CHANGE
OIL STRAINER CLEANING

OIL PRESSURE CHECK

2-4

·OIL PUMP

2-5
2-10

FINAL DRIVE OIL

IB

2-10
2-11

CONTROL CABLE LUBRICATION
LUBRICATION POINTS

SERVICE INFORMATION
GENERAL
To service the oil pump, it is necessary to remove the right side cover and water pump assembly. See section 6 for water pump
removal and installation.

SPECIFICATIONS
Engine oil
.....

Oil capacity

3.0 liter (3.2 US qt, 2.6 Imp qt) after draining
3.5 liter (3.7 US qt, 3.1 Imp qt) afler disassembly

I

-~

rOil reco;,mendation.

Use HONDA 4-STROKE OIL or equivalent.
r·.
API SERVICE CLASSIFICATION: SE or SF. I
VISCOSITY: SAE 10W-40

OIL VISCOSITIES CHART

r·
!

Other viscosities shown in the chart may be
used when the averane temperature in your
riding area is within the indicated range.

SAE IOW-40
SAE IOW-30

I
·

0

l-<o

l. ~;: ~;:"wit

t.

Oil pump del ive~-

..-..

5.4:. 0.7 kg/cm

2

20
-10

40

o

6G
10

80

~c:

20

100

•F

.:o •c

(77 :±. 10 p5i) at 5,000 rpm (80°C/176°F)

- 28.8 Iiter (30.5 __
u_s_q_t_ll_m_i_n_·a_t_5_.o_o_o__
rP_fl_l___________________________________

1

Oil pump service data

···-

Rotor tip clearance

·-_0~.1:=AmNORD6i

n=)=-=--=--- =~-r

0.15-0.22 mm (0.006-0.009 in)

Pump hody clearance

.

SERVICE LIMIT

0.20 mm (0.008 in)

0.35 mm (0.014 in)

.. - - - - - - - - - - - - - 1

I

I.

Pump end clearn~

_________j_ ·-~_?Y7.!01

=-~?3

0.10 mm (0.004 in)

in 1

Final drive gear
'R~:

Oil capacity
Recommended oil

AftP.r
'83:
.. -·- .........·---------------1
------------+-·--150 cc (5.1 ozl after disussembly

170 cc (57 oz.) after disassembly
130 cc (4.4 ot.l after draining
Hypoid gear oil

Above 5''C/41<• F SAE 1'90
'
,,
Below 5 C;41 F SAE .:;:80!
(

(.'

130 cc (4.4

01.)

after

<lrain~

Hypoid gear oil SAE

~80

2-1

LUBR ICATION
TORQUE VA LUES
Engine oil drain plug
Engine oil filter
Oil pressure switch

35- 40 N-m (3.5-4.0 kg -m, 25 -29 ft-lb)
15- 20 N-m (1.5-2 .0 kg -m, 11 - 14 ft-lb) - Apply Loctite0) to crankcase bolt thread s.
10-- 14 N·m !1.0- 1.4 kg-m, 7- 10 ft-lb)
· Apply 3-BOND!!>) or its equivalent to the
bolt thread s.

T OO LS
Special
Oil pres sure gauge
Oil pressure gauge attachment

07506-3000000]. IIy ava1.1abl e eqUiva
. Ient.
or commercia
_
075 10 4220 100

TROUBLESHOOTING
Oil l evel too low
1. External o il leaks
2. Worn piston ri ngs
3. Worn valve guide or seal
Oil contam ination

1. Oil or filter not changed often enough

2. Head gasket faulty
3. Worn piston rings
Low oil pressure
1. Oil level low
2 . Pressure relief valve stuck open
3. Plugged oil pick -up screen
4 . Oil pum p worn
5. Extern al oi l leaks
High oil pressure
1. Pressure relief valve stuck open
2. Plugged oil filter, gallery, or m etering orifice
3. Incorrect oil being used
No oil pressu re
1. Oil level low
2. Oil pump drive chain broken
3. Oil pump faulty
4 . Internal o il leakage

2-2

LUBRICATION

ENGINE OIL LEVEL
Put the motorcycle on its center stand on level
ground. Start the engine and let it idle for 2-3
minutes. Turn off the engine. Remove the dipstick,
wipe it clean and insert it without screwing it in.
Remove the dipstick and check the oil level.
If the level is below the lower level mark, remove
the filler cap and fill to the upper level mark.
Check the oil pressure with the warning indicator
switch after the engine starts. The indicator should
go off after one or two seconds.
If it does not, stop the engine and check the oil
pump fu nction and/or oil circuit.

ENGINE OIL & FILTER CHANGE
NOTE:
Change engine oil with the engine warm and
the motorcycle on its center stand to assure
complete and rapid draining.
Stop the engine.
Remove the canister (California model only).
Remove the oil filler cap, cylinder head oil drain
plug, engine bottom oil drain plug and drain the oil.
Remove the oil filter with a filter wrench and let the
remaining oil drain out. Discard the oil filter.
Make sure that the sealing washers on the drain
plugs are in good condition, then install the plugs.
After completely draining the oil replace the oil
filter with a new one. Check that the oil filter O·ring
is in good condition, and coat it with oil before
installing it. Fill the crankcase with 3.0 liters (3.2
US qt, 2.6 Imp qt) of the recommended oil (page

OIL FIL TEA 15-20 N·m
(1.5-2.0 kg·m, 11-14 ft·lb)

2·1).
Start the engine and let it idle for 2-3 minutes,
then stop the engine.
Make sure that the oil level is at the upper level
mark.
Make sure that there are no oil leaks.

DRA IN PLUG 35-40 N·m
(3.5-4.0 kg-m, 25-29 ft-lb)

·-

.I

CYLINDER HEAD OIL DRAIN PLUG
10-14 N·m (1.0- 1.4 kg·m, 7-10 ft-lb)

2-3

LUBRICATION

OIL STRAINER CLEANING
NOTE:
The oil strainer can be removed with the
engine mounted in the frame.
Remove the front exhaust pipes.
Drain the engine oil (page 2-3).
Remove the oil pan bolts and oil pan.

OIL PAN

Remove and clean the oil strainer.
Check the operation of the pressure relief valve.
Make sure the 0-ring is in good condition when·
ever the relief valve is removed.
Install the oil strainer and oil pan.
Install the exhaust pipes.
Fill the crankcase with the recommended oil (page
2-1) .

OIL PRESSURE CHECK
Warm the engine up to normal operating temper·
ature (approximately 80°C/176° F).
Stop the engine and disconnect the oil pressure
switch wire.
Remove the oil pressure switch and connect an
oil pressure gauge to the pressure switch hole
(page 2-5) .
Check the oil level.

2-4

LUBRICATION
O IL PRESSURE GAUGE
07506-3000000
StiJrt the engine and check the oil pressure at 5,000
rpm.
OIL PRESSURE :
5.4 ± 0.7 kg/cm 2 (77 ± 10 psi) at 5,000 rpm
(80° C/176° F)
Stop the engine.
Apply 3·BOND® sealant or equivalent to the
pressure switch threads and install.
TORQUE : 10- 14 N·m (1.0- 1.4 kg-m, 7-10 ft-lb)
Connect the oil pressure switch w ire.
Start the engine.
Operate the warning indicator switch.
Check that the oil pressure warning indicator goes
out after one or two seco1.ds.
If the oil pressure warning ind icator stays on, stop
the engine immediately and determine the cause.

PR
ATIACHMENT 07510-4220100

OIL PUMP
REMOVAL
NOTE:
The oil pump can be removed w ith t he engine
mounted in the frame.
Drain the engine oil. Remove the exhaust system.
Remove the right side cover.
Remove the oil pump driven sprocket by removing
the bolt and washer.
Remove the water pump assembly (page 6-1 0).

OIL PASS PIPE
Remove the oil strainer (page 2-4) and the oil
pass pipe.
Make sure the 0 -rings are in good condition.

0 -RINGS

2-5

LUBRICATION
MOUNTING BO LT

Remove the oil pump by removing the mounting
bolts.

OIL PUMP
STRAI NER STAY

O·RING

Straighten and remove the pin holding the oil
strainer st ay.
Remove the oil st rainer stay.
Make sure the O·rings are in good conditions.

DOWEL PI N

DISASSEMBLY
Remove the oil pump body cover and remove the
dowel pin.
Remove the drive pin from the rotor shaft.

OI L PUMP BODY COVER

2-6

LUBRICATION

Measure the rotor tip clearance.
SER V ICE LIMIT: 0.20 mm (0.008 in)

Measure the pump body clearance.
SERV ICE LIMIT: 0.35 mm (0.01 4 in)

Remove the rotor shaft and measure the pump
end clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)

2-7

LUBRICATION
ASSEMBLY
Install the outer rotor into the body and insert the
rotor shaft.
Insert the drive pin into the rotor shaft.

01 L PUMP BODY

OUTER ROTOR

\

ROTOR SHAFT

DRIVE PIN

Align the slots in the inner rotor with the drive pin.

DRIVE PIN
DOWEL PIN

Install the dowel pin and oil pump body cover.

2-8

INNER ROTOR

LUBRICATION
INSTALLATION
Install the dowel pins and 0 -ring and install the
oil pump.
Install the strainer stay with a new pin and install
the oil pipe.
NOTE:
Make sure the 0-rings are installed on the
strainer stay and oil pipe.
Install the oil strainer and oil pan.

0-RING

Place the oil pump driven sprocket into the drive
chain.
NOTE:
The "IN" mark on the driven sprocket should
face the crankcase.
Install the washer and tighten the bolt.
Install the dowel pins and a new gasket.
Install the right side cover.
Install the water pump assy (page 6-11).
Install the exhaust pipe.
Fill the engine with the recommended oil (page
2-1 ).
DRIVEN SPROCKET

2-9

LUBRICATION

FINAL DRIVE OIL

OI L FILLER CAP

CHECK
Place the motorcycle on its center stand on level
ground.
Remove the oil filler cap.
Check that the oil level reaches the lower edge of
the oil filler cap hole.
Check for leaks, if the level is low. Pour fresh oil
through the oil filler hose until it reaches the lower
edge.

CHANGE
Remove the oil filler cap and drain bolt to drain all
oil from the final gear case.
Install the drain bolt securely.
Fill the gear case with the recommended oil up to
the correct level (above).
OIL CAPACITY : 130 cc (4 .4 oz)
RECOMMENDED OIL :

'83:
HYPOID GEAR 01 L API,
GL-5 SAE #90 (Above 5°C/41°F)
SAE # 80 (Below 5°C/41°F)
After '83:
HYPOID GEAR OIL: SAE #80

OIL LEVEL

CONTROL CABLE LUBRICATION
Periodically, disconnect the thrc:fttle cables at their
upper ends. Thoroughly lubricate the cables and
their pivot points with a commercially available
cable lubricant or a light weight oil.

2-10

LUBRICATION

LUBRICATION POINTS

~

., ICABLE LUBRICANT I

..--fiiiiW

THROTTLE GRIP

THROTTLE AND
CHOKE CABLES

SWING ARM
PIVOT

... ~

BRAKE
PEDAL IPIVOT
I
I
I

...--fiiiiW
or

I CABLE LUBRICANT I

SPEEDOMETER CABLE

I
I

DRIVEN FLANGE
SPINDLES AND
PINS
(LITHIUM BASED
MULTIPURPOSE
GREASE)
I

I

I

I

I

I

I

I

I
I

I

..--fiiiiW
FOOT PEG
PIVOT

...--fiiiiW
SPEEDOMETER
DRIVE GEAR
FRONT FORK
(A.T.F.)

SHIFT
PEDAL PIVOT

FINAL DRIVE
GEAR AND SHAFT
SIDE AND
(HYPOID GEAR
CENTER
OIL API, GL-5
STAND
PIVOT
DRIVE SHAFT SA #80-#90)
JOINT
(LITHIUM BASED
MULTIPURPOSE
GREASE)

2-11

,-- - - · - - -- - - --

3. MAINTENANCE
- - -- - - - -·-·----

! SERVICE INFORMATION

3-1

CYLINDER COMPRESSION

3-3

EVAPORATIVE EMISSION CONTROL 3-17
SYSTEM
< CHASSIS >

FU EL FILTER
THROTTLE OPERATION

3-5
3-5
3-6

CARBURETOR CHOKE

3-7

AIR CLEANER

3-7

BRAK E PAD WEAR

3-19

CRANKCASE BREATHER

3-8

BRAKE SYSTEM

3-19

SPARK PLUGS

3-8

BRAKE LIGHT SWITCH

3-20

IGNITION SYSTEM

3-9

HEADLIGHT AIM

VALVE CLEARANCE

3-9
3-14

3-20
3-20
3-21

MAINTENANCE SCHEDULES
< ENGINE >
FUEL LINES

CARBURETOR SYNCHRONIZATION

3-17

BATTERY

3-18

BRAKE FLUID

3-18
3-18

After '84 : FRONT BRAKE LEVER

CLUTCH
After '84: CLUTCH LEVER
SID E STAND

3-21

SUSPENSION

3-21

RADIATOR CORE

3-15
3-16
3-16

WHEELS

3-23

COOLING SYSTEM HOSES

3-16

STEERING HEAD BEARINGS

3-23

NUTS, BOLTS, FASTENERS

3-23

CARBURETOR IDLE SPEED
RADIATOR COOLANT

SERVICE INFORMATION
GE NERAL
•
•
•

Engine oil
Engine oi l fil t!!r
Final d ri ve gear oil

See page 2 3
See page 2-3
See page 2-10

SPE CI FICATIONS
< Engine>
Spark plugs:

[ __

DP~ ;EKA : 9 .

Spark plug gap:

Stan dard

0

.x2~ R.=_'-!9 _L

_

I

Fo r_cold cl1 mate (below 5" C, 41 " FJ

:' P~9_-

+.X 2~R

.

lJg · · I

For ex t ended h igh sper.d r id i11 g

NG K

ND

OPR9EA-9

X27EPR U9

0.8-0.9 mm (0.031 - 0.035 in )

3-1

•

MAINTENANCE
Ignit ion tim ing
At idle :
Advance starts:
Full advance:

10° BTDC
10° 8TDC at 1,500 rpm
3i' BTDC at 3,800 rpm

Valve clearance
Cold (Below 35'' c . 95"' FJ:

Intake/ Exhaust: 0.15 mm (0.006 in)

Idle speed:
Carburetor synchronization:
Cylinder compression :
Throttle grip free play:

1.000 ± 100 rpm
A ll carburetors within 60 mm !2.4 in) Hg
13 .t 21<g/cm 2 (184 ± 28 psi)
2 -6 mm (1/8-1/4 in)

<CHASSIS >
Tire:

Cold t ire pressure. psi (kPa, kg/ cm 2

Up to 90 kg (200 lbs)
load
)

90 kg (200 lbs) load

···--- ····-··- --1· ·-- L.

- -·

;

Bri dgestone

;

Dunlop

--------·--------- --·-·--.J.__

Front fork air pre ssure: 0- 6 psi (0~4

M1 10/90-18

M 140/90-16

32 1225, 2 .251

32 (225, 2.25)

32 (225 , 2 .25 1

40 (280, 2.80)

- - - - ·-

! to vehicle capaci ty load

T ire brand

Rear

Front

Tire size

r···---..F, ,

L303

I,

..

L...... .

- - - - · · ----- ··'"

G508H
K627

k Pa , 0-·0.4 kg / cm 1 )

TORQUE VALUES
Valve adju st ing nut

21· 25 N·m !2.1

2.5 kg -m, 15- 18 ft·lb)

TOOLS
Special
Vac:uum gauge se t
Carburetor pilot screw w rench
Compression gau9e attachment
Valve ad justing w rench
Flywheel cover
A cl justing wrench IA l
Camshaft holder

3-2

07404-0030000 or M937B- 021 - XXXXX (U .S.A. only)
07908-4220201
0751 O-M BOO 101 -Equivalent commercially ava il able in U .S.A.
07908-M BOO 100
07998·· MBOOOOO
07708-0030300 -Equi valent commerciall y avai lable i n U.S.A .
07979 ·MK30000

MAINTENANCE

MAINTENANCE SCHEDULES
'83, '84, '85:
Perform the PRE -RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.

1: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A : ADJUST, L: LUBRICATE
FREQUENCY

ITEM
FUEL LINES
FUEL FILTER
THROTTLE OPERATION

*
*

*
*

~

r-+~A_IRCLENOTl437

CRANKCASE BREATHER
SPARK PLUGS

c
w

~

r-+~

~

r.~-+4

r-+~VAL_ECRN

ENGINE OIL

....1

~ ~=

Z

0

(/)
(/)

:E
W

r-+

*
r-+~

*
r.~-+1

*

•

••

I

CARBUETO~HK

E~NG:IOL=fTR

NOTE 2
-~+4

__________+-~3

=~

CARBURETOR-SYNCHRONIZATION
-~+4
CARBURETOR-IDLE SPEED
~-+4r~;
RADIATOR COOLANT
RADIATOR CORE

=~YEAR:

YEAR

=~

COOLING SYSTEM HOSES &
CONNECTIONS
EVAPORATIVE EMISSION
CONTROL SYSTEM

STEERINGHEADBEARINGS

C
~-4
R

t·kj/yf'{f/

I

I
I

I
I

C
R

R

R

I
I

I
I
I
I

R~ =~

I
NOTE 3

I

R=~

I

C
R

C
R

I
R
I
I
C
R

~7

3-8
3-8
-~

79

R

I
I
I
I

I
I
*A
I

3-14
3-15
3-16
3-16

R~ ~=

I

~2-3=

2-3

__~

R

~= R: =~
I

C
R

3-5
3-5
3-6

I

1

1

3·16

I

1

1

3-17

.lf f)f It l] ,"litf}l .. t.I' If;• '_N;

3-23

* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND
SERVICE DATA AND IS MECHANICALLY QUALIFIED.
**IN THE INTEREST OF SAFETY, WE RECOMMENDED THAT THESE ITEMS BE SERVICED ONLY BY AN AUTHOR ·
IZED HONDA DEALER.
NOTES: 1.
2.
3.
4.

SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS.
SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE (U.S.A. ONLY).
'84 CALIFORNIA MODEL ONLY.
FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE.

3 -3

MAINTENANCE
AFTER '85
Perform the Pre-ride Inspection at each scheduled maintenance period.
1: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A;ADJUST, L: LUBRICATE

~EVR

FREQUENCY

ITEM

(/)

~

*
*

FUEL LINES

*

THROTTLE OPERATION

*

CARBURETOR-CHOKE

w
t0

w
t-

<(

..

FIRST

..
'

#~

EVERY

~

~if

., *~

*~

..

_f ~ _f ~ *~

~ &~ ~ 0 #f0 #~
&'$
9~·
o .!:;- ,.~ c:o·~

.... 0

""

q,•.....

.... .....

.... "

I

I

I

I

~ _f ~ *~
0
#~ ~

~ #~
o·~

CRANKCASE BREATHER

NOTE 2

R

SPARK PLUGS

Refer
to page
3-5

R

3-5

I

3-6

I

3-7

R

3-7
3 -8

I

I
NOTE 1

1\i "

I

FUEL FIL TEA

AIR CLEANER

..,..4'

1\i "

c

c

c

c

c

c

R

R

R

R

R

R

3-8

I

I

I

I

3-11

VALVE CLEARANCE

w

I

ENGINE OIL

R

R

R

R

2·3

z

ENGINE OIL FILTER

R

R

R

CARBURETOR-SYNCHRONIZATION

I

I

R
I

I

2·3
3-14

I
*R

3-15
3-16

I

3-16

I

3-17

A

2-10

1 ~

3-18

..J

a:

0

U5
(/)

*

..

~

w

*
*

CARBURETOR-IDLE SPEED

I

RADIATOR COOLANT
RADIATOR SYSTEM

I

EVAPORATIVE EMISSION
CONTROL SYSTEM

NOTE 3

-

BRAKE PAD WEAR

w
t-

..

BRAKE SYSTEM

*

HEADLIGHT AIM
CLUTCH FLUID

0

<(
..J

w

a:

z

0

~

z
0
z

-.. ~ t'''

SUSPENSION

**

WHEELS

**

NUTS, BOLTS, FASTENERS
STEERING HEAD BEARINGS

,,

·''

-~

I
-~

.

'•,, I"': I '

j

-"'
- •,.

.'

---"-- - ·- 'c
i

:'

.;
'

>··' _. ..- -·-

,J, }:

"

'I

_'l'•
"\

I ·~ ~

_:::_I

i'-'

I·•

t'

'

~

·: :/ 1

"' ~';
I]_

.

"' I '

~

, ,-

-~:.·

'{_""!-'-'
1

"',\;

f

i 1,''
~

~; r :

.::.. t

... '

_, ,}'-

I! •'

• J'ii:

' _i_;:__ ..••,

~-

i '" P'
1 ~

.\l::· I;'- 1.•~

''I

I ' .·' ~-; >•

'-.

·'- --"'' ,--,-',

I! t -,

fl

-~ L

I•"' ---"-

'::.

1:1 0

t-? jR"

'• I>· I"" L'

'·

1..,111;:-t.; 1<-

;,R ) I 0:• 1 1.

~

:c':

'

..

'

.

. ., I ' ~} t
1 ~. It f'·
·; 11- ~

.:·,

2 YEARS "R

SIDE STAND

*
**

..

l•r

BRAKE LIGHT SWITCH

CLUTCH SYSTEM

U5
(/)
w

MONTH ·c··

Z___..,.._...,..._.
YEARS *R'

BRAKE FLUID

I

,,

l li

p.·

'··

I

I
I

I
~ ~-:;

BATTERY

~

w
t-

I

I

FINAL DRIVE OIL
(/)

I

I
I

2 YEARS *R

~

-

lt)'R•
i ~·".'

I •
J
J
'ilfi

~- ~·-

l:'_ ~- .:£

...~ ~. ~ ~

r

?.f' -: "- .: ~'

~:'J

3-19
3-20
3-20
3-20

• I

3-20

I

3-21

-.,.:.:.!!: :/.it." 1"-c I

_, l_' ~o' 1' ..{·: L~
-.::. f i•' -~
~ I

3-18
3-19

j

I

3-21

L

3-23

'\
k_

3-23
3-23

* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND
SERVICE DATA AND IS MECHANICALLY QUALIFIED.
**IN THE INTEREST OF SAFETY, WE RECOMMENDED THESE ITEMS BE SERVICED ONLY BY AN ATUHORIZED
HONDA DEALER.
NOTES: 1.
2.
3.
4.

3-4

SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS.
SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN, OR AT FULL THROTTLE.
CALIFORNIA TYPE ONLY.
FOR HIGHER ODOMETER READING, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE.

MAINTENANCE

FUEL LINES
Remove the left and right side covers, and seat.
Make sure the fuel tank is less than half-full.
Drain it, if it is more than half-full.
Remove the tank mounting bolts, lift the fuel tank
up and hold it in place with the tank support rod.

TANK MOUNTING BOLT
S UPPORT ROD
Check the fuel lines and replace any parts which
show deterioration, damage, or leakage.
Disengage the tank support rod by lifting the tank
slightly. Let the fuel tank down into place and
install the mounting bolts. Be careful not to pinch
or kink the vent and fuel lines.

FUEL FILTER

\

FUEL FILTER HOLDER

Remove the seat.
Remove the fuel filter from the holder.
Unclip the fuel lines.
Disconnect the fuel lines from the fi lter.
Replace the fuel filter with a new one when indicat·
ed by the maintenance schedule. (See page 3·31
Install the fuel filter .

Gasoline is flammable and is explosive under
certain conditions. Do not smoke or allow
flames or sparks in your working area.
After installing, check that there are not fuel leaks.
~

FUEL F ILTER

FUEL LINE

3-5

MAINTENANCE

THROTTLE OPERATION
Check for smooth throttle grip full opening and
automatic full closing in all steering positions.
Check the throttle cables and replace them if they
are deteriorated, kinked, or damaged.
Lubricate the throttle cables (page 2-11 I, if throttle
operation is not smooth.
Measure throttle grip free play at the throttle grip
flange.
FREE PLAY: 2-6 mm (1/8-1/4 in)

LOCK NUT
Adjustment can be made at either end of the
throttle cable. Minor adjustments are made with the
upper adjuster and major adjustments are made with
the lower adjuster after lifting the fuel tank up.
Adjust by loosening the lock nut and turning the
adjuster.
Tighten the lock nut and recheck throttle operation.
Lower fuel tank into place and check throttle free
play once more.

UPPER ADJUSTER

LOCK NUT

3-6

MAINTENANCE

CARBURETOR CHOKE

CHOKE LEVER

The V65 choke system uses a fuel enrichening
circuit controlled by a bystarter valve. The by·
starter valve opens the enrichening circuit via cable
when the choke lever on the handlebar is pushed up.
Check for smooth upper choke lever operation.
Lubricate the choke cable, if the operation is not
smooth.
Push the choke lever on the handlebar all the way
up to fully open. Make sure the choke valve is
open by trying to move the choke lever on the
carburetor, after lifting the fuel tank up.
There should be no free play.
Adjust if necessary, by loosening the choke cable
clamp on the carburetor and moving the choke
cable casing so the choke lever is fully open.
Tighten the clamp.
CABLE CLAMP
Pull the choke lever all the way to fully closed.
Make sure the choke valve is fully closed by checking for free play in the cable between the lever on
the carburetor and cable casing.
Reinstall the removed parts in the reverse order of
disassembly.

CHOKE CABLE

AIR CLEANER
Make sure the fuel tank is less than half·full. Drain
it, if it is more than half-full.
Remove the tank mounting bolts and lift the fuel
tank up and hold it in place with the tank support
rod.
Remove the air cleaner cover screws.

AIR CLEANER COVER

3-7

MAINTENANCE
AIR CLEANER ELEMENT

Remove the air cleaner element and discard it in
accordance with the maintenance schedule.
Also, replace the element any time it is excessively
dirty or damaged.
Install a new element and install the cover.
Disengage the tank support rod by lifting up slighty.
Let the fuel tank down into place and install the
fuel tank mounting bolts. Be careful not to pinch or
kink the vent and fuel lines.

CRANKCASE BREATHER
Remove the plug from the drain tube to empty any
deposits.
Install the drain plug.
NOTE:
Service more frequently when riding in rain
or at full throttle, or if the deposit level can
be seen in the transparent section of the drain
tube.

SPARK PLUGS
RECOMMENDED SPARK PLUGS
NGK

NO

Standard

DPRSEA-9

X24EPR-U9

For cold climiate
(Below 5°C, 41°F)

DPR7EA·9

X22EPR·U9

For extended
high speed riding

DPR9EA-9

X27EPR-U9

DRAIN PLUG
CENTER
ELECTRODE

SIDE ELECTRODE

Disconnect the spark plug caps.
Clean any dirt from around the spark plug bases.
Remove and discard the spark plugs.
Measure the new spark plug gaps using a wire-type
feeler gauge.
SPARK PLUG GAP: 0.8-0.9 mm (0.031-0.035 in)
Adjust by bending the side electrode carefully.
With the plug washer attached, thread each spark
plug in by hand to prevent crossthreading.
Tighten the spark plugs another 1/2 turn with a
spark plug wrench to compress the plug washer.
Connect the spark plug caps.

3-8

'

MAINTENANCE

IGNITION SYSTEM

ALTERNATOR COVER

NOTE:
The ignition system is transistorized and can·
not be adjusted. If the ignition timing is incorrect, check the spark unit and pulse generator and replace any faulty parts (Section

19).
Remove the alternator and left crankcase covers.
Install a flywheel cover (07998-MBOOOOO).
Wipe off the oil from the flywheel.
Connect the timing light to the high tension wire
of the No. 1 cylinder.
Start the engine and let it idle.

I D LE SPEED: 1,000 ± 100 rpm
The timing is correct if the "F" mark on the flywheel aligns with the crankcase rear mating surface.

VALVE CLEARANCE
'83, '84, '85:
NOTE:
Inspect and adjust valve clearance while the
engine is cold. (Below 35°C, 95°F)
Remove the heat guard, radiator cap, and drain bolt.
Drain coolant from engine and frame (page 6·3).
NOTE:
Drain the coolant into a clean container for
reuse. Scheduled coolant replacement is every
2 years or 24,000 miles (38,600 km).
Remove the right and left frame side covers and
remove the seat.
Lift up the fuel tank by removing the front mou nt·
ing bolts. Be sure the tank is less than half-full.
If not, drain the tank.
Remove the spark plug caps and the spark plugs.

SIDE COVER

3-9

MAINTENANCE
IGNITI ON COILS

CYLINDER HEAD COVER

Remove the ignition coils with their bracket and
remove the insulator cover.
Remol.le the radiator (See page 6-6) .
Remove the front and rear cylinder head cover bolts
and both cylinder head covers.
Remove the alternator cover.

INSPECTION
Measure and adjust the intake and exhaust valve
clearances as described below.
Rotate the crankshaft clockwise to align the T1 - 3
mark with the crankcase mating surfaces.
Make sure the No. 1 p iston is at TDC (Top Dead
Center) on the compression stroke.

INSULATOR COVER

Insert the camshaft holder as shown and tighten it.
Check the valve clearance for the No. 1 cylinder
using two feeler gauges for each pair of valves.
VALVE CLEARANCE (IN. EX):
0 .15 mm (0.006 in)
If adjustment is necessary, loosen the lock nuts and
turn the adjusting screws until there is a slight drag
on both feeler gauges. Both feeler gauges should
remain inserted during adjustment.
Hold the adjusting screws and tighten the lock nuts.
TORQUE: 2 1-25 N·m (2.1-2.5 kg-m, 15- 18 h-lb)

CAUTION :
The lock nuts will come loose if not tightened
to the co"ect torque value.

REAR CRANKCASE MATING SURFACE

Recheck the valve clearance.
Rotate the crankshaft 270° clockwise to align the
T2-4 mark with the crankcase mating surfaces and
check the valve clearances for No. 2 cylinder using
No. 1 cylinder procedure.
Adjust if necessary using the procedure for No.
cylinder.
Rotate the crankshaft 90° clockwise to align the
Tl-3 mark with the crankcase mating surface and
check the valve clearance for No.3 cylinder.
Adjust using the procedures for No. 1 cylinder.
Rotate the crankshaft 270° clockwise to align the
T2- 4 mark with the crankcase mating surface and
check the valve clearance for No.4 cylinder.
Adjust if necessary using the procedure for No.
cylinder.

3-10

J;

CAMSHAFT HOLDER
07979-MK30000

VALVE ADJUSTING WRENCH
07908-MBOOl 00

MAINTENANCE

Install the removed parts, except the radiator cap,
in the reverse order of disassembly.
Be sure the cast mark inside the rear cylinder head
cover faces the front and the tabs of the front cylinder head cover face the rear.
Check the engine oil level.
Fill and bleed the cooling system (page 6-3).

REAR CYLINDER HEAD COVER

AFTER '85:
NOTE:

~spect

and adjust valve clearance wh ile the
_ _35°
___
__F)
_ _ _ _ _ _ _ _ __ J
engme is cold. (Below
C,_ _
95°
NOTE:
Drain the coolant into a clean container for
reuse. Scheduled coolant replacement is every
2 years or 24,000 miles (38,600 km) .

Remove the right and left frame side covers and
remove the seat.
Lift up the fuel tank by removing the front mountIng bolts. Be sure the tank is less than half-full.
If not, drain the tank.
Remove the spark plug caps and the spark plugs.

SIDE COVER '
OVER FLOW TUBE

Remove the right and left radiator side covers.
Disconnect the over flow tube at the radiator filler
neck.

SCREWS

3-11

MAINTENANCE
Remove the left steering head cover attaching nut
and cover.

FAN MOTOR COUPLER

Disconnect the fan motor coupler.

Disconnect the thermostatic switch wire from the
switch and turn the radiator valve to "SHUT".
Loosen the coolant drain plug on the sub frame
(page 6·3) once to release coolant pressure, then
retighten the drain plug.
Loosen the lower radiator hose band and disconnect
the lower radiator hose from the subframe.

RADIATOR VALVE

Remove the air chamber cover screw and right air
chamber cover.

3-12

MAINTENANCE
RAD IATOR
Remove the radiator mounting bolts.
Slide the radiator to the right and suspend it from the
handlebar with a piece of wire.

Remove the ignition coils with their bracket and
remove the insulator cover.
Remove the front and rear cylinder head cover bolts
and both cylinder head covers.

CYLI NDER HEAD
COVER

INSPECTION
Remove the alternator cover.
Turn the flywheel clockwise until the "T1-3" mark
aligns with the crankcase mating surfaces in compression stroke.
Make sure that the No. 1 piston is at TDC (Top
Dead Center) on the compression stroke.
Insert the camshaft holder as shown and tighten it.
Check the valve clearance for the No. 1 cylinder
usi ng two feeler gauges for each pair of valves.

VALVE CLEARANCE (IN. EX):
0 .15 mm (0 .006 in)
If adjustment is necessary , loosen the lock nuts and
turn the adjusting screws until there is a slight drag
on both feeler gauges. Both feeler gauges should
remain inserted during adjustment.

07979-MK30000

3-13

MAINTENANCE

Hold the adjusting screws and tighten the lock nuts.
TORQUE: 21-25 N·m (2.1-2.5 kg-m, 15-18 ft·lb)

CAUTION:
The lock nuts will come loose if not tightened
to the co"ect torque value.
Recheck the valve clearance.
Rotate the crankshaft 270° clockwise to align the
T2-4 mark with the crankcase mating surfaces and
check the valve clearances ior No. 2 cylinder using
No. 1 cylinder procedure.
Adjust if necessary using the procedure for No. 1
cylinder.
Rotate the crankshaft 90° clockwise to align the
Tl -3 mark with the cranl<case mating surface and
check the valve clearance for No. 3 cylinder.

/jJ
VALVE ADJUSTING WRENCH
07908-MBOOlOO

Adjust using the procedures for No. 1 cylinder.
Rotate the crankshaft 270° clockwise to align the
T2- 4 mark with the crankcase matmg surface and
check the valve clearance for No.4 cylinder.
Adjust if necessary using the procedure for No. 1
cylinder.
Install the removed parts, except the radiator cap,
in the reverse order of disassembly.
Be sure the cast mark inside the rear cylinder head
cover faces the front and the tabs of the front cylin·
der head cover face the rear.
Check the eng1ne oil level.
Turn the radiatorvalveto "OPEN" (see page 3 -12).
Fill and bleed the cooling system (page 6-3).

REAR CYLINDER HEAD COVER

Install the radiator cap.
NO. 1 CY LINDER
HEAD PORT PLUG

CARBURETOR SYNCHRONIZATION
NOTE
Synchronize the carburetors with the engine
at normal operating temperature, transmission
in neutral, and motorcycle on the center stand.
Remove the plugs from the No. 1, 2. 3 and 4 cylin·
der head ports and install the vacuum gauge adapters.
Connect the vacuum gauges.

3-14

MAINTENANCE
ADJUSTMENT

VACUUM GAUGE 07404- 0030000
or M937B-021-XXXXX (USA only)

NOTE
The No. 1 carburetor cannot be adjusted; It is
the base carburetor.
Start the engine and adjust the idle speed.
ID LE SPEED: 1,000 ± 100 rpm

Install the vacuum gauge adapter and connect the
vacuum gauge.
Check that all carburetors are within 60 mm (2.4 in)
Hg.

Synchronize to specification by turning the adjusting screws with the special tool.

CARBURETOR PILOT SCREW
WRENCH 07908- 4220201

Recheck the idle speed and synchronization.
Remove the gauge adapters and install the plugs.

CARBURETOR IDLE SPEED

THROTTLE STOP SCREW

NOTE
• Inspect and adjust idle speed after all other
engine adjustments are within specifications.
• The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is
sufficient.
Warm up the engine, shift to NEUTRAL, and place
the motorcycle on its center stand.
Turn t he throttle stop screw as requi red to obtain
the specified idle speed.
IDLE SPEED: 1,000 ± 100 rpm

3-15

MAINTENANCE

RADIATOR COOLANT

RESERVE TANK CAP

Remove the frame right side cover.
Check the coolant level of the reserve tank with the
engine runing at normal operating temperature.
The level should be between the "UPPER" and
"LOWER" level lines.
If necessary, remove the reserve tank cap and fill to
the "UPPER" level line with a 50/ 50 mixture of
distilled water and anti-freeze.
Reinstall the cap and frame side cover.

RADIATOR CORE
Check the air passages for clogging or damage.
Straighten bent fins and collapsed core tubes.
Remove insects, mud, or any obstruction with com·
pressed air or low water pressure.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.

COOLING SYSTEM HOSES
Inspect the hoses for cracks or deterioration, and
replace if necessary .
Check the tightness of all hose clamps.

WATER HOSES

3-16

MAINTENANCE

CYLINDER COMPRESSION
Warm up the engine.
Stop the engine, then disconnect the spark plug
caps and remove the spark plugs.
Insert the compression gauge.
Open the throttle all the way and crank the engine
with the starter motor.
NOTE:
Crank the engine until the gauge reading
stops rising. The maximum reading is usually
reached within 4·7 seconds.
COMPRESSION PRESSURE:
13 ± 2 kg/cm 2 (184 ± 28 psi)
If compression is low, check for the following:
- Improper valve clearance
- Leaky valves
- Leaking cylinder head gasket
- Worn piston/ring/cylinder

AU
07510-MB00101
COMPR
COMMERCIALLY AVAILABLE IN U.S.A.

'84, '85:

PURGE CONTROL VALVE
TO
AIR VENT ATMOSPHERE
CONTROL _,
VALVE
.
2

PURGECONT~LV

If compression is high, it indicates that carbon
deposits have accumulated on the combustion
chamber and/or the piston crown.

EVAPORATIVE EMISSION CONTROL
SYSTEM (California model only)

AFTER '85:

( ~ (i

\
~

\

~-

. ~->;\,
I,

\._---

~

-

Check the system hoses for damage, deterioration,
clogging, or loose connections.
Check the charcoal canister for cracks or damage.

CARBURETOR PIP ING

'84, '85:

J'

,........-""

CANISTER

Refer to the vacuum hose routing diagram label for
the hose connections.

I.

CANISTER

AFTER '85:

NOTE:
Be careful not to bend, twist, or kink the
tubes when installing.
Slide the end of each tube onto its fitting
fully and secure with hose clamps.
Secure with the hose clamps whenever
specified.
Check that the hoses do not contact sharp
edges or corners.

VACUUM HOSE ROUTING DIAGRAM
EHQINE FAMILf GHN109844C3
EVAPORATIVE fAMILY telC
CAUFORNIA VEHICLE

j
I ~-850

3-17

MAl NTENANCE

<CHASSIS>
BATTERY

HOLDER BOLT

UPPER LEVEL LINE

Remove the right frame side cover and inspect the
battery fluid level.
When the fluid level nears the lower level, remove
the battery and add distilled water to the upper
level line as follows:
Remove the battery holder bolt and pull out the
battery. Disconnect the negative cable at the battery
terminal, then disconnect the positive cable.
Remove the filler caps and add distilled water to
the upper level line. Reinstall the battery.
NOTE:
Add only distilled water. Tap water will
shorten the service life of the battery.

The bauery electrolyte contains sulphuric
acid. Protect your eyes, skin, and clothing.
If electrolyte gets in your eyes, flush them
thoroughly with water and get prompt
medical attention.

UPPER LEVEL MARK

BRAKE FLUID
Check the brake fluid reservoir level.
If the level nears the lower level mark, fill the reservoir with DOT-4 BRAKE FLUID to the upper
level mark.
Check the entire system for leaks.

CAUTION:
Do not remove the cover until the handlebar has been turned so that the reservoir is
level.
• A void operating the brake lever with the
cap removed. Brake fluid will squirt out if
the lever is pulled.
Do not mix different types of fluid, as they
are not compatible.

LOWER LEVEL MARK

After '84:

Refer to section 17 for brake bleeding procedures.

LOWER LEVEL MARK

INDEX MARK

FRONT BRAKE LEVER
After '84:

.I

Measure the distance the front brake lever moves
before the brake starts to take hold.
The lever free play should be 20-30 mm (3/41-1 /4 in.) at the tip of the brake lever.
If adjustment is necessary, turn the adjuster.

CAUTION:

~Align

I'----f~dex

the a"ow on the brake lever with the
mark on the adjuster.

Apply the brake lever several times and rotate the
front wheel to check for excessive drag.

3-18

I
ADJUSTER

MAINT ENANCE

BRAKE PAD WEAR
Check the brake pads for wear by looking through
the slot indicated by the arrow cast on the caliper
assembly.
Replace the brake pads if the wear line on the pads
reaches the edge of the brake disc (page 17-5).

CAUTION:
Always replace the brake pads in pairs to
assure even disc pressure.

BRAKE DISC

ARROW

BRAKE SYSTEM
Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. Tighten any
loose fittings.
Replace hoses and fittings as required.

ARROW

BRAKE PEDAL HEIGHT

LOCK NUT

Adjust brake pedal height so the pedal is 30 mm
(1-1/4 in) above the top of the footpeg.

CAUTION:
Jnco"ect brake pedal heijht can cause brake
drag.
To Adjust:
Loosen the stopper bolt lock nut and turn the
stopper bolt.
Retighten the lock nut.
NOTE:
After adjusting the brake pedal height, check
the rear brake light switch and brake pedal
free play and adjust if necessary.

3-19

MAINTENANCE

BRAKE LIGHT SWITCH

BRAKE LIGHT SWITCH

NOTE:
Perform brake light switch adjustment after
adjusting the brake pedal play and height.
Adjust the brake light switch so that the brake
light will come on when the brake engagement
begins.
Adjust by holding the switch body and turning
the adjusting nut. Do not turn the switch body.
NOTE :
The front brake light switch does not require
adjustment.

ADJUSTING NUT
CASE MOUNTING BOLT

HEADLIGHT AIM
Adjust horizontally by loosening both headlight
bracket mounting bolts.
Adjust vertically by loosening both headlight case
mounting bolts.
NOTE:

---------------------------.

Adjust the headlight beam as specified by
local laws and regulations.

An improperly adjusted headlight may blind
oncoming drivers, or it may fail to light the
road for a safe distance.
BRACKET MOUNTING BOLT

CLUTCH

UPPER LEVEL MARK

r-------------------.
After '84:

Check the clutch fluid reservoir level.
If the level nears the lower level mark, fill the
reservoir with DOT -4 BRAKE FLUID to the upper
level mark.
Check the entire system for leaks.

CAUTION:
-------Do not remove the cover until the handlebar has been turned so that the reservoir
is level.
A void operating the clutch lever with the
cap removed. Fluid will squirt out if the
lever is pulled.
Do not mix different types of fluid, as
they are not compatible.

3-20

LOWER LEVEL MARK

LOWER LEVEL MARK

MAINTENANCE

CLUTCH LEVER
After '84 :

A fter '84:

ARROW

Measure the distance the clutch lever moves before
the clutch starts to disengage.
Lever free play should be 20-30 mm (3/4-1-1 /4
in.~
at tip of the lever. If adjustment is necessary,
turn the adjuster.

'

CAUTI ON:

r---

----------------------------.

Align the index mark on the adjuster with the
.I a"ow on the lever.

ADJUSTER

SIDE STAND
Check the rubber pad for deterioration or wear.
Replace if any wear extends to wear line as shown.
Check the side stand spring for damage and loss of
tension, and the side stand assembly for freedom
of movement. Make sure the side stand is not
bent.

GOOD

NO GOOD

NOTE:
• When replacing, use a rubber pad with the
mark "Over 260 lbs ONLY".
Spring tension is correct if the measurements fall within 2-3 kg (4.4- 6.6 lb),
when pulling the side stand lower end with
a spring scale.

0

X

SUSPENSION
Do not ride a vehicle with faulry suspension.
Loose, worn, or damaged suspension parts
impair vehicle stability and control.

FRONT
Check the action of the front forks by compressing
them several times.
Check the entire fork assembly for leaks or damage.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.

3-21

MAINTENANCE
'83, '84, '85:

AFTER '85:

Check the front fork air pressure when the forks
are cold.
Place the vehicle on its center stand.
Remove the air valve cap and measure the air
pressure.
AIR PRESSURE :
0-6 psi (0--40 kPa, 0-0.4 kg/cm 2 )

AIR VALVE CAP

ANTI -DIVE SYSTEM INSPECTION

Selecr a safe ploce alWy from traffic to
perform rhis inspecrion.
Check the operation of the anti·dive system by
riding the motorcycle and firmly applying the
brakes.
Position

Anti-dive damper force

I
II
Ill
IV

LIGHT ANTI-DIVE
MEDIUM
HARD
MAXIMUM ANTI-DIVE

Inspect and, if necessary, repair the system (Refer
to section 15).

REAR
Place the motorcycle on its center stand.
Move the rear wheel sideways with force to see if
the swingarm bearings are worn.
Replace the bearings if there is any looseness (page
16-15).
Check the shock absorbers for leaks or damage.
Tighten all rear suspension nuts and bolts.

3-22

ADJUSTER

MAINTENANCE

WHEELS
NOTE:

Tire pressure should be checked when tires
are COLD.
Check the tires for cuts, imbedded nails, or other
sharp objects.
RECOMMENDED TIRES AND PRESSURES:
Front

Rear

M1 10/90-18

M140/90-16

32
(225, 2.25)

32
(225, 2.251

32
(225, 2.25)

40
(280, 2.8)

BRIDGESTONE

L303

G508

DUNLOP

F11

K627

Tire size
Up to
90 kg
Cold
(200 lbs)
tire
load
pres90 kg
sure
(200 li?SI
psi
load ttl
(kPa,
kg/cm 2 I vehicle
capacity
load
Tire
brand

Check the front and rear wheels for trueness (Sec·
tions 15 and 16).
Measure the tread depth at the center of the tires.
Replace the tires if the tread depth reaches the
following limit:
Minimum tread depth:
Front: 1.5 mm (1/16 in)
Rear:
2.0 mm (3/32 in)

STEERING HEAD BEARINGS
NOTE:

Check that the control cables do not interfere with handlebar rotation.
Raise the front wheel off the ground and check
that the handlebar rotates freely.
If the handlebar moves unevenly, binds, or has
vertical movement, adjust the steering head bearing
by turning the steering head adjusting nut (page
15-4).

NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened
to their correct torque valul!s (Section 1) at the
intervals shown in the Maintenance Schedule (page
3-3).

Check all cotter pins, safety clips, hose clamps,
and cable stays.

3-23

4. FUEL SYSTEM
SERVICE INFORMATION

CARBURETOR ASSEMBLY

4- 1
4-2
4-3
4-5
4-6
4-8
4 - 10
4 - 12

CARBURETOR INSTALLATION

4- 16

TROUBLESHOOTING
CARBURETOR REMOVAL
VACUUM CHAMBER
FLOAT CHAMBER
PILOT SCREW
CARBURETOR SEPARATION

PILOT SCREW ADJUSTMENT

4-16
4-17
4-17
4- 18
4-18
4-19

FUEL TANK
AUXILIARY FUEL TANK
AIR CLEANER
FUEL PUMP
HIGH ALTITUDE ADJUSTMENT
(USA only)

Ill

EVAPORATIVE EMISSION CONTROL 4 -20
SYSTEM (California model only)
AIR VENT CONTROL VALVE

4-21

SERVICE INFORMATION
GENERA L
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke
or allow flames or sparks in the work area.
• The front cyl inders use down draft carburetors.
• When disassembling fuel system parts, note the locations of the 0-rings. Replace them with new ones on reassembly.
• The float bowls have drain screws that can be loosened to drain residual gasoline.
• Fuel pump inspection is in section 21.
• The No. 1 and No.3 carbu retors use different jet needles (thinner) and shorter springs than the No. 2 and No. 4 carburetors.
Do not interchange these parts.
'85:
•

Refer to the label on the air cleaner cover below the fuel tank for the hose connections of the evaporative emission control
system (California model only).

After '85:
• All hoses used in the evaporative emission control system are numbered for identification. When connecting one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label , page 1-19 (California model only). for its
correct routing and connection.

TOOLS
Special
Valve guide driver, 7 mm
Vacuum pump
Pressure pump

07942-8230000 (U.S.A. only)
ST- AH-260- MC7 (U.S.A. only)
ST- AH-255-MC7 (U.S.A . only)

Common

Float gauge

07401-0010000

SPECIFICATIONS
'83
Venturi dia.
Identification No.
Float level
Main jet
Idle speed
Throttle grip free play
Pilot screw initial opening

'84, '85

After '85

~

.....
~

~

Primary
12.0 mm (0.48 in)
Secondary 33.2 mm (1.31 in)

-

-

VD70A

VD70C (California : VD76A)

VD79A

6.0 mm (0.24 in)

7.5 mm (0.29 in)

8.0 mm (0.31 in)

Front # 140

#11 8

#1 15

Rear

#1 20

# 118

# 140

1,000 ± 100 rpm

~

2- 6 mm (0.08- 0.24 in)

~

See page 4-16

~

~

~
~

-

4-1

FUEL SYSTEM

TROUBLESHOOTING
Engine cranks but won't start
1. No fuel in tank
2. No fuel to carburetor
3. Engine flooded with fuel
4. No spark at plug {ignition system faulty)
5. Air cleaner clogged
6. Intake air leak
7. Improper choke operation
8. Improper throttle operation
9. Faulty purge control valve
Hard starting or stalling after starting
1. Improper choke operation
2. Ignition malfunction
3. Carburetor faulty
4. Fuel contaminated
5. Intake air leak
6. Idle speed incorrect
7. Faulty purge control valve
Rough idle
1. Ignition system faulty
2. Idle speed incorrect
3. Incorrect carburetor synchronization
4. Carburetor faulty
5. Fuel contaminated
Misfiring during acceleration
1. Ignition system faulty
Backfiring
1. Ignition system faulty
2. Carburetor faulty
Poor performance {driveability) and poor fuel economy
1. Fuel system clogged
2. Ignition system faulty

4-2

lean m ixture
1. Clogged fuel jets
2. Vacuum piston stuck closed
3. Faulty float valve
4. Float level low
5. Fuel cap vent blocked
6. Fuel strainer screen clogged
7. Restricted fuel line
8. Air vent tube clogged
9. Intake air leak
10. Restricted or faulty fuel pump
Rich mixture
1. Clogged air jets
2. Faulty float valve
3. Float level too high
4. Choke stuck or clogged
5. Dirty air cleaner

FUEL SYSTEM

CARBURETOR REMOVAL
Disconnect the air vent tube and remove the air
vent cut-off valve. (After '85: Cal ifornia model
only).

AIR VENT CUT-OFF VALVE

Check that the fuel tank is at least one-half empty.
Otherwise, drain the fuel tank until it is one-half
empty before raising the tank.
Remove the seat and front fuel tank mounting
bolts. Lift the fuel tank up and put the support
arm down.

AIR CHAMBER COVER

Remove the air cleaner cover and element.
Remove the right and left air chamber covers.

Remove the bolt attaching the thermostat housing
to the air chamber and the ground cable.

4-3

FUEL SYSTEM
Remove the six screws and the air chamber top
cover.
Disconnect the breather tube.

Remove the carburetor choke clamp and disconnect
the choke and throttle cables.

CHOKE CABLE

CLAMP

Loosen the carburetor bands and remove the carburetor assembly from the left side.
NOTE :

It may be necessary to loosen the engine
mount bolts and move the engine on its
rubber mounts to provide clearance for carburetor removal.

CARBURETOR BANDS

4-4

FUEL SYSTEM

VACUUM CHAMBER

SCREWS

REMOVAL
Remove the four vacuum chamber cover screws and
cover.

CAUT ION
Do not interchange vacuum chamber covers,
springs, pistons or jet needles between carburetors.

Remove the compression spring, diaphragm, and
vacuum piston.
Inspect the vacuum piston for wear, nicks,
scratches, or other damage.
Make sure the piston moves up and down freely in
the chamber.
Note that the No. 1 and No. 3 carburetors use
thinner jet needles and shorter springs than the
No. 2 and No. 4 carburetors.

Push the needle holder in and turn it 60 degrees
with an 8 mm socket. Then remove the needle
holder, spring and needle from the piston.

4-5

FUEL SYSTEM

Inspect the needle for excessive wear at the tip and
for bending, or other damage.

DIAPHRAGM

Check the diaphragm for deterioration and tears.

NEEDLE HOLDER

INSTALLATION
Installation is essentially the reverse of removal.
Install the chamber cover so that its cavity aligns
with the hole in the diaphragm.
Be sure the thinner jet needles and shorter springs
are installed in the No. 1 and No. 3 carburetors.

FLOAT CHAMBER

FLOAT CHAMBER

REMOVAL
Remove the four float chamber screws and the float
chamber.

SCREWS

4-6

FUEL SYSTEM
FLOAT LEVEL
Measure the float level with the carburetor inclined
15°-45° from vertical and the float tang just
contacting the float valve.
SPECIFICATION: '83:
6.0 mm (0.24 in)
'84, '85: 7.5 mm (0.29 in)
After '85: 8.0 mm (0.31 in)
NOTE:
Measure the float level nearest the float valve.
'83, '84, '85:
Adjust the float level by carefully bending the float
tang.
.After '85:
Replace the float assembly if it is out of specifica·
tion.

FLOAT AND JETS

FLOAT

FLOAT PIN

Remove the float pin, float, and float valve.

Inspect the float valve for grooves and nicks.
Inspect the operation of the float valve.

VALVE SEAT

4-7

FUEL SYSTEM
FLOAT VALVE

T

Remove the starter jet, main jet, and slow jet.
Remove the float valve seat and filter .

FILTER
Inspect the float valve seat and filter for grooves,
nicks, or deposits.

ASSEMBLY
Assemble the float chamber components in the
reverse order of disassembly.

PILOT SCREW
REMOVAL
NOTE :
The pilot screws are factory pre-set and
should not be removed unless the carburetors are overhauled.
The pilot screw plugs are factory installed
to prevent pilot screw misadjustment. Do
not remove the plugs unless the pilot
screws are being removed.
• Cover all opening with tape to keep metal
particles out when the plugs are drilled.

Center punch the pilot screw p lug to center the
drill point.
Drill through the plug with a 4 mm (5/32 in) drill
bit, being careful not to drill into the pilot screw.

CAUTION:
Be careful not to drill into the pilot screw.
All pilot screws must be replaced even if only
one requires it for proper pilot screw adjustment (page 4-16).

4-8

VALVE SEAT

FUEL SYSTEM

Force a self-tapping 4 mm screw (H/C 069399,
P/N 93903-3541 0) into the drilled plug and
continue turning the screwdriver until the plug
rotates with the screw.
Pull on the screw head with pliers to remove the
plug.
Use compressed air to clean the pilot screw area and
remove metal shavings.

Turn each pilot screw in and carefully count the
number of turns before it seats lightly.
Make a note of this to use as a reference when
reinstalling the pilot screws.

CAUTION
Damage to the pilot screw seat wi/1 occur if
the pilot screw is tightened against the seat.
Remove the pilot screws and inspect them. Replace
them if they are worn or damaged.

PILOT SCREW

INSTALLATION
Install the pilot screws and return them to their
original position as noted during removal.
Perform pilot screw adjustment if new pilot screws
are installed (page 4-16).
NOTE
Do not install new plugs on new pilot
screw holes until after adjustment has been
made.
• If you replace the pilot screw in one car·
buretor, you must replace the pilot screws
in the other carburetors for proper pilot
screw adjustment.

4-9

FUEL SYSTEM

CARBURETOR SEPARATION
Remove the screws attaching the air chamber to the
carburetors and separate the chamber and carburetors.

SCREWS
CHOKE RODS AND LEVERS
Remove the nuts, and remove the choke levers and
rods.
Remove the cotter pins and washers, and remove
the choke rod.

CHOKE ROD

Carefully separate the No. 3 carburetor from the
assembly. Then separate the No. 4 carburetor.

No. 1 CARBURETOR
No.2 CARBURETOR

CAUTION
Separate the carburetors horizontally to prevent damage to the joint pipes.

No.4 CARBURETOR
SYNCHRONIZATION THRUST
No.3 CARBURETOR SPRINGS
SPRINGS

4-10

FUEL SYSTEM

Disconnect the throttle link from the No. 1 and
No. 2 carburetors by removing the cotter pins.

THROTTLE LINK
FUEL JOINT PIPE

No. 1 CARBURETOR

Carefully separate the No. 1 and No. 2 carburetors.

No. 2 CARBURETOR
CHOKE ARM

SPRING

COLLAR

Remove the choke arm collar and remove the choke
arm and spring.
Remove the choke valve nut, spring, and valve.

NUT

4-11

FUEL SYSTEM

Check the choke valve and spring for nicks, grooves,
or other damage.

l•

CHOKE VALVE

CARBURETOR ASSEMBLY

ARM

SPRING

VALVE

SPR ING

Install th e choke valve, valve spring, and nut and
tighten the nut.
Install the choke arm and spring while hooking the
arm to the groove in the c hoke valve. Install the
choke arm collar.

NUT

COLLAR

FUEL JOINT PIPE
Coat the new O·rings with oil and install them on
the fuel joint pipe for No. 1 and No. 2 carburetors.
Install the fuel joint pipe to the No. 1 and No. 2
carburetors.

O·RINGS

4-12

FUE L SYSTEM
THROTTLE LINK
Reconnect the throttle linkage between the No. 1
and No. 2 carburetors, using new cotter pins.

No. 2 CARBURETOR

COTTER PINS

No.1 CARBU RETOR

FUEL JO INT PIPE
Coat new 0-rings with oil and install them on the
fuel and air joint pipes.
Put the No. 3 and No. 4 carburetors together with
the joint pipes.

AIR JO INT PIPES
THRUST SPRING

No.3 CARBUR ETOR

Loosen the synchronization adjusting screws until
there is no tension.
Install the synchronization springs.
Install the thrust springs between the throttle valve
shafts.

No.3 SYNCHRO NI ZATI ON SPR ING

4-13

FUEL SYSTEM
No.2 CARBURETOR

THRUST SPRING

No.4 CARBURETOR

Make sure the fuel joint and air joint pipes are
securely installed.

No.4 SYNCHRONIZATION
No.2 SYNCHRONIZATION
SPRING
SPRING
CHOKE RODS AND LEVERS

Install the choke rods and levers, using the nuts and
new cotter pins.

CHOKE ROD
FUNNEL

GROMMETS

Make sure the air chamber funnels, grommets, and
dowel pins are in place.

DOWEL PINS

4-14

FUEL SYSTEM

Place the air chamber over the carburetors aligning
the dowel pins with the carburetor holes.
Attach the air chamber to the carburetors with the
eight screws.

SCREWS
BY-PASS HOLE
Turn the throttle stop screw to align the No.
throttle valve with the edge of the by-pass hole.

No.1 CARBURETOR

THROTTLESTqPSCREW

No.3 ADJUSTING SCREW
Align each throttle valve with the by-pass hole edge
by turning the synchronization adjusting screws.
Inspect throttle operation as described below:
• Open the throttle slightly by pressing the throttle
linkage. Then release the throttle.
• Make sure that it returns smoothly.
• Make sure that there is no drag when opening
and closing the throttle.
Make sure that choke valve operation is smooth by
moving the choke linkage.
Close the choke valve by turning the choke linkage.
Release the choke linkage and make sure that it
returns smoothly.

4-15

FUEL SYSTEM

CARBURETOR INSTALLATION
Install the air vent cut-off valve and connect the air
vent tube (After '85 California model only).
Installation is essentially the reverse of removal.
NOTE
Route the throttle and choke cables properly
(pages 1-10through 1-15).
Perform the following inspections and adjustments.
Throttle operation (page 3·6).
• Carburetor choke (page 3-7).
Carburetor idle speed (page 3-15).
Carburetor synchronization (page 3-14).

PILOT SCREW ADJUSTMENT
IDLE DROP PROCEDURE (U.S.A. ONLY)

AIR VENT CUT·OFF VALVE
PILOT SCREW

NOTE
• The pilot screws are factory pre·set and no
adjustment is necessary unless the pilot
screws are replaced (page 4·8).
• Use a tachometer with graduations of 50
rpm or smaller that will accurately indicate
a 50 rpm change.
1. Turn each pilot screw clockwise until it seats
lightly and back it out to the specification
given. This is an initial setting prior to the final
pilot screw adjustment.
INITIAL OPENING:
'83:
3 turns out
'84-'85: 2·3/4 turns out
3 turns out (California only)
After '85: 2-1/2 turns out

CAUTION:
Damage to the pilot screw seat will occur
if the pilot screw is tightened against the
seat.
2. Warm up the engine to operating temperature.
Stop and go driving for 10 minutes is sufficient.
3. Attach a tachometer according to its manufac·
turer's instructions.
4. Adjust the idle speed with the throttle stop
screw.
IDLE SPEED: 1,000 ± 100 rpm
5. Turn each pilot screw 1/ 2 turn out from the
initial setting.
6. If the engine speed increases by 50 rpm or
more, turn each piiot screw out by a continual
1/ 2 turn until engine speed drops by 50 rpm or
less.

4-16

THROTTLESTOPSCREW

FUEL SYSTEM
7. Adjust the idle speed with the throttle stop
screw.
8. Turn the No. 1 carburetor pilot screw in until
the engine speed drops 50 rpm.
9. Turn the No. 1 carburetor pilot screw 1 turn
out from the position obtained in step 8.
10. Adjust the idle speed with the throttle stop
screw.
11. Perform steps 8, 9 and 10 for the No.2, 3 and
4 carburetor pilot screws.
12. Drive new pilot screw plugs into the pilot screw
bores with a 7 mm valve guide driver (P/N 07942
-8230000). When fully seated the plug surfaces
will be recessed 1 mm into the pilot screw bore.

FUEL TANK
Do not allow flames or sparks near gasoline.
Wipe up spilled gasoline at once.
Check the vent hole of the filler cap for blockage.
Check that fuel is flowing out of the fuel valve
freely. If fuel flow is restricted, clean the fuel
strainer.
Make sure that there are no fuel leaks.

AUXILIARY
FUEL TANK

AUXILIARY FUEL TANK

MOUNTING BOLT

Drain fuel from the main and auxiliary tank.
Remove the seat, main fuel tank, and side covers.
Remove the regulator/rectifier.
Disconnect the battery negative cable, then positive
cable and remove the battery.
Remove the rear wheel (page 16 -3) .
Remove rear fenders A and B.
Detach the auxiliary fuel tank hose from the fuel
pump.
Disconnect the fuel level sensor wire terminals.
Remove the auxiliary fuel tank mounting bolt and
tank.
Install the auxiliary fuel tank in the reverse order of
removal.
LEVEL SENSOR

REGULATOR/RECTIFIER

4-17

FUEL SYSTEM

AIR CLEANER
CASE/CHAMBER
Check the air cleaner case for deterioration.

CRANKCASE VENTILATION SYSTEM
Check that the breather tube is not restricted.

FUEL PUMP

FUEL PUMP

COUPLER

Remove the seat and side covers.
Disconnect the fuel pump coupler.
Remove the fuel pump mounting bolts.
Disconnect the fuel lines from the pump and
remove the pump.
NOTE:

Before disconnecting the fuel lines, turn the
fuel valve off and clamp the fuel lines to
prevent the fuel from flowing out.

MOUNTING BOLT

4-18

FUEL SYSTEM

HIGH ALTITUDE ADJUSTMENT (USA only)
When the vehicle is to be operated continuously
above 2,000 m (6,500 feet) the carburetor must be
readjusted as follows to improve driveability and
decrease exhaust emissions.
Warm up the engine to operating temperature. Stop
and go driving for 10 minutes is sufficient.
Remove each pilot screw plug (page 4-8) .
Turn each pilot screw clockwise 1 turn.
Adjust the idle speed to 1,000 ± 100 rpm with the
throttle stop screw.
Drive new pilot screw plugs into the pilot screw
bores (page 4-17).
NOTE:
This adjustment must be made at high altitude to ensure proper high altitude operation.
Attach a Vehicle Emission Control Information
Update label onto the frame as shown. Refer to
Service Bulletin #SL 132 for information on obtaining the label.
NOTE:
Do not attach the label to any part that can
be easily removed from the vehicle.

Operation at an altitude lower than 1,500 m
(5,000 feet) with the carburetor adjusted for
high altitudes may cause the engine to idle
roughly and stall.
When the vehicle is to be operated conti·
nously below 1,500 m (5,000 feet), turn each
pilot screw counterclockwise I turn to its
original position after removing each pilot
screw plug and adjust the idle speed to 1,000
± 100 rpm. Drive new pilot screw plugs into
the pilot screw bores (page 4·17). Be sure to
do these adjustments at low altitude.

VEHICLE EMISSION CONTROL
IN.FORMATION UPDATE LABEL

4-19

MAINTENANCE

EVAPORATIVE EMISSION CONTROL
SYSTEM (California model only>

'84, '85:

After '85:

VACUUM HOSE ROUIING DIAGRAM

PURGE CONTROL VALVE (PCV)
INSPECTION

UIII(IUUIIIIO.IICl
lVIrtllliYl 1~
I'll

tlliiiiUIIIIOICU

VACUUM HOSE ROUTING DIAGRAM
ENOINlPAMII.V OHN1011..Cl
IVAP'O,.ATIYII PAlMI. Y- IIZC
CAUf-OfiiNIA VIHtCLI:

' ,c.v

AVC.V.

•wo

NOTE:
The purge control valve should be inspected if
hot restart is difficult.

~"12

~

~

"

l lll llll

Disconnect the PCV hoses from their connections
and rem011e the PCV from its mount. Refer to the
routing label diagram on the frame behind the left
side cover.

Connect a vacuum pump to the hose that goes to
the No. 2 carburetor body. Apply the specified
vacuum to the PCV.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuum should be maintained.
Replace the PCV if vacuum is not maintained.

TO 2.4
CARBURETORS
TO CHARCOAL )
CANISTER
......- ....._.,-r~v

PURGE CONTROL VALVE

TO 1, 3
CARBURETORS

TO NO.2
CARBURETOR
BODY

CAUTION:
To prevent damage to the purge control valve,
do not use high air pressure sources. Use a
hand operated air pump only.
VACUUM PUMP
ST·AH·260-MC7 (U.S.A. only)

Plug the hose that goes to the No. 2, 4 carburetors.
Remove the vacuum pump and connect it to the
hose that goes to the No. 1, 3 carburetor bodies.
Apply the specified vacuum to the PCV.

BLOCKED TUBE

SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuum should be maintained.
Replace the PCV if vacuum is not maintained.

I

VACUUM PUMP
ST·AH·260·MC7 (U.S.A. only)

4-20

FUEL SYSTEM

Connect a pressure pump to the 8 mm I.D. hose
that goes to the charcoal canister. While applying
the specified vacuum to the PCV hose that goes to
the No. 2 carburetor body, pump air through the
canister hose. Air should flow through the PCV and
out the hose that goes to the No. 1, 3 carburetor
body. Replace the PCV if air does not f low out.

PRESSURE PUMP
ST·AH-255-MC7 (U.S.A. only)

Remove the pump, install the PCV on its mount.
route and reconnect the hoses according to the
routing label.

AIR VENT CONTROL VALVE
(California model only, AFTER

VACUUM PUMP
ST-AH-260-MC7 (U.S.A. only)

/

'8~

AIR VENT CONTROL VALVE (AVCV)
INSPECTION

TO OPEN AIR

•

AIR VENT CONTROL
,-,..__ _ _ VALVE

Disconnect the AVCV hoses from their connections
and remove the AVCV from its mount. Refer to the
routing label on rear fender behind the seat for hose
connections.
Connect a vacuum pump to the hose that goes to
the No.3 cylinder intake port.
Apply the specified vacuum to the A VCV.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuum should be maintained.
Replace the AVCV if vacuum is not maintained.

CAUTION:

TO N0.3
CYLINDER
INTAKE PORT
VACUUM PUMP
ST-AH-260-MC7 (U.S.A. only)

To prevent damage to the air vent control
valve, do not use high air pressure sources.
Use a hand operated air pump only.

Connect the vacuum pump to the air vent port of
the AVCV.
Apply vacuum to the AVCV. The vacuum should
hold steady.
Replace the AVCV if vacuum leaks.

1

VACUUM PUMP
ST-AH-260-MC7 (U.S.A. only)

4-21

FUEL SYSTEM

Connect the vacuum pump to the hose that goes to
the No. 3 cylinder intake port.
Connect the pressure pump to the air vent port of
the AVCV.
While applying the vacuum to the AVCV hose that
goes to the No. 3 cylinder intake port, pump air
through the air vent port.
Air should flow through the AVCV and out the
hose that goes to the carburetor air joint pipe.
VACUUM PUMP
ST-AH-260-MC7 (U.S.A. only)

I

Plug the hose that goes to the carburetor air joint
pipe.
While applying vacuum to the AVCV hose that goes
to the No. 3 cylinder intake port, apply air pressure.
It should hold steady.
Replace the AVCV if pressure is not retained.
Remove the pumps, install the AVCV on its mount,
route and reconnect the hoses according to the
routing label.

PRESSURE PUMP
ST-AH-255-MC7 (U.S.A. only)

BLOCKED
TUBE

4-22

VACUUM PUMP
ST-AH-260-MC7 (U.S.A. only)

ENGINE REMOVAL/INSTALLATION

35-45 N·m
(3.5-4.5 kg·m,
25- 33 ft-lb)

35- 45 N·m
(3.5- 4.5 kg-m,

85-105 N·m
(8.5-1 0.5 kg-m,
61-76 ft·lb)

25-33\bl

20- 30 N ·m
(2.0-3.0 kg - m.~
14- 22 ft·lb)
45-70 N·m
(4.5-7.0 kg-m,
33-51 ft-lb)

~

\

8-14 N·m
(0.8-1.4 kg·m,
6-10 ft-lb)

5-0

18-28 N:m
---(1.8-2.8 kg-m,
18- 28 N·m
13- 20 ft-lb)
(1.8- 2.8 kg·m,
13-20 ft·lb)

8- 12 N·m (0.8- 1.2 kg·m,
6-9 ft·lb)

5.
. - - -- - --

ENGINE REMOVAL/
INSTALLATION

- -- - - ·---····· .

SERVICE INFORMATION

5-1

ENGINE REMOVAL

5-2

ENGINE INSTALLATION

5-5

SERVICE INFORM ATJON
GENERAL
•
•

A fl oor jack or other adjustable support is required to support and maneuver the engine.
The fo llowing parts or compon ents can be serviced with the engine installed in the frame:
Clutch
Gearshift linkage
Cylinder heads

A lternator
Starter motor
Carburetors

SPEC I FICATIONS
Engine dry weight
Oil capacity

96.7 kg (213.2 lb)
3.5liters (3.7 U.S. qtl

TOR QUE VALU ES
Engine hanger bolt
8 mm bolt
10 mm bolt
Sub-frame bolts
Upper
Lower
Rear axle nut
Rear axle pinch bolt
Final gear case nut

20-30 N -m (2.0- 3.0 kg·m, 14-22 ft·lb )
35- 45 N -m (3.5- 4.5 kg·m. 25-33 ft· lb)
60- 70 N-m (6.0- 7.0 kg·m, 43-51 h-lb)
35-45 N-rn (3.5- 4 .5 kg·m, 25-33 ft-lb)
85-105 N-m (8.5- 10.5 kg-m, 61 -76 ft· lh)
20-30 N -m (2.0--·3.0 kg·m. 14-22 ft-lb)
45-70 N-m (4.5- 7 0 kg·m, 33-5 1 ft·lb)

5-1

ENGINE REMOVAL/INSTALLATION

•
•
•

ENGINE REMOVAL
Place the motorcycle on its center stand.
Remove the seat and raise the fuel tank.
Remove the left and right frame side covers.
Drain the engine oil (page 2·3) and the coolant
(page 6·3).
Remove the rear wheel (page 16·3).
Remove the radiator (page 6·6).
Remove the carburetor (page 4·3).
Remove the exhaust chamber mount bolt.
Remove the exhaust muffler mount bolts and joint
nuts.
Loosen the exhaust pipe clamp bolts and remove
the exhaust mufflers.

,/~

CLAMP CHAMBER
JOINT NUTS
BOLT
MOUNT BOLT OIL PRESSURE SWITCH AND
PULSE GENERATOR WIRE COUPLER

Disconnect the wire couplers for the alternator, oil
pres.s ure switch, and pulse generator.
Remove the wire clamp
Disconnect the spark plug caps.

•
ALTERNATOR
WIRE COUPLER

Remove the bolt attaching the ground cable to the
crankcase and disconnect the ground cable.

5-2

WIRE CLAMP

SPARK PLUG
WIRE

•
•
•

ENGINE REMOVAL/INSTALLATION

Disconnect the starter motor cable .

CRANKCASE REAR COVER

Remove the crankcase rear cover.

AFTER '85:

Remove the crankcase rear cover front bracket.
Remove the clutch slave cylinder.
NOTE:

Do not operate the clutch lever after removing
the clutch slave cylinder. To do so will cause
difficulty in reinstalling the slave cylinder.

CRANKCASE REAR COVER
FRONT BRACKET

5-3

ENGINE REMOVAL/INSTALLATION
WATER PUMP HOSE BAND
Remove the gearshift arm from the shift spindle.
Loosen the water pump hose band.

GEARSHAFT INDICATOR
SWITCH WIRE COUPLER
Disconnect the gearshift indicator switch coupler
and remove the wire clamp.

WIRE BAND
BREATHER TUBE
Disconnect the crankcase breather tube.
Place a floor jack or other adjustable support under
the engine.
NOTE:
The jack height must be continuously adjust·
ed so that mounting bolts can be removed,
and so stress is relieved from other bolts until
they are re moved.
Remove the engine mounting bolts.
Remove the left sub-frame bolts and the sub-frame.
Remove the engine from the left side.

LEFT SUB-FRAME

5-4

ENGINE REMOVAL/INSTALLATION

ENGINE INSTALLATION
Check the engine mount rubbers for damage or wear
and replace if necessary.
Install the engine mount rubbers.
Engine installation is essentially the reverse of
removal.
Use a floor jack or other adjustable support to
carefully manuever the engine into place.

CAUTION:
Carefully align mounting points with the jack
to prevent damage to mounting bolt threads
and wire harness and cables.
Tighten all fasteners to the torque values given on
page 5-1.
NOTE
• Route the wires and cables prope,rly (page

1·9).
Fill the crankcase to the proper level with
the recommended oil (page 2-1).
• Fill the cooling system (page 6 ·3).
• Perform the following inspection and adjustments:
Throttle operation (page 3-6) .
Clutch (page 3-20}.

5-5

ENGINE REMOVAL/INSTALLATION

Install the exhaust system:
Install new exhaust pipe joint gaskets.
Assemble the left and right exhaust pipes.
Tighten the exhaust pipe band loosely and install
the exhaust pipes.
Hand tighten all bolts and nuts, the n torque them
in the order given below:
1. Tighten the exhaust pipe joint nuts.
TORQUE : 8-14 N·m
(0.8-1.4 kg-m, 6-10 ft-lb)

2. Tighten the exhaust chamber mounting bolt.
TORQUE: 8-12 N·m
(0.8-1.2 kg-m, 6-9 ft-lb)

3. Tighten the rear muffler hanger setting bolts.
TORQUE : 18-28 N·m
(1.8-2.8 kg-m, 13-20 ft-lb)

4. T ighten the exhaust pipe joint band bolts.
TORQUE: 18-28 N·m
(1.8-2.8 kg-m, 13-20 ft-lb)

5-6

COOLING SYSTEM

'83, '84, '85:

'

---

6-0

--

- - --!

6. COOLING SYSTEM
SERVICE INFORMATION

6-1
6- 1
6-2
6-3

TROUBLESHOOTING
SYSTEM TESTING
COOLANT REPLACEMENT

THERMOSTAT
RADIATOR/COOLING FAN
WATER PUMP

6-4
6-6
6-10

SERVICE INFORMATION
GENERAL

Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result.
The engine must be cool before servicing the cooling system.
•
•
•
•
•
•

Use only distilled water and ethylene glycol in the cooling system. A 50-50 mixture is recommended for maximum corrosion protection. Do not use alcohol-based antifreeze.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be made with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a cooling system tester.
Refer to Section 21 for fan motor thermostatic switch and temperature sensor inspections.

SPECIFICATIONS
Radiator cap relief pressure

0.75-1.05 kg/cm 2 (10.7-14.9 psi)

Freezing point

55% Distilled water+ 45% ethylene glycol: -32°C (-25°F)
50% Distilled water+ 50% ethylene glycol: -37°C (-34°F)
45% Distilled water+ 55% ethylene glycol: -44.5°C (-48°F)

Coolant capacity:
Radiator and engine
Reserve tank
Total system

3.0 liters (3.2 US qt)
0.45 liters (0.5 US qt)
3.45 liters (3.65 US qt)
3 .2 liters (3.38 US qt)

'83, '84, '85:
After '85:

Thermostat

Begins to open: 80° to 84°C (176° to 183° F)
Valve lift: Minimum of 8 mm at 95°C (0.315 in. at 203°F)

Boiling point (with 50-50 mixture):

Unpressurized: 107.7°C (226°F)
Cap on, pressurized: 125.6°C (258°F)

TOOLS
Special
Cooling system tester

Commercially available in U.S.A.

TROUBLESHOOTING
Engine temperature too high
1. Faulty temperature gauge or gauge sensor
2. Thermostat stuck closed
3. Faulty radiator cap
4. Insufficient coolant
5. Passages blocked in radiator, hoses, or water jacket
6. Fan blades bent
7. Faulty fan motor

Engine temperature too low
1. Faulty temperature gauge or gauge sensor
2 . Thermostat stuck open
Coolant leaks
1. Faulty pump mechanical seal
2. Deteriorated 0-rings

6-1

COOLING SYSTEM

SYSTEM TESTING
COOLANT
Test the coolant mixture with an antifreeze tester.
For maximum corrosion protection, a 50-50%
solution of ethylene glycol and distilled water is
recommended.

RESERVE TANK

RADIATOR CAP INSPECTION
Pressure test the radiator cap. Replace the radiator
cap if it does not hold pressure, or if relief pressure
is too high or too low. It must hold specified
pressure for at least six seconds.
NOTE

Before installing the cap on the tester, apply
water to sealing surfaces.
RADIATOR CAP RELIEF PRESSURE:
0.75-1.05 kg/cm 2 (10.7-14.9 psi)

RADIATOR CAP

Pressurize the radiator, engine, and hoses, and check
for leaks.

CAUTION:
Excessive pressure can damage the radiator.
Do not exceed 1.05 kgfcm 2 (14.9 Psi)
Repair or replace components if the system will not
hold specified pressure for at least six seconds.

6-2

COOLING

TESTER

COOLING SYSTEM

COOLANT REPLACEMENT

RADIATOR CAP

CAUTION:
The engine must be cool before servicing the
cooling system, or severe scalding may result.
Remove the radiator cap.

Drain the coolant from the radiator by removing the
drain plug located at the lower left sub-frame.

Drain the coolant from the engine by removing the
drain bolts at the water pump cover and cylinder
heads.
Replace the drain plug and bolts.
Fill the system with a 50-50 mixture of distilled
water and ethylene glycol.
Bleed air from the radiator.
• Start the engine and run until there are no air
bubbles in the coolant, and the level stabilizes.
• Stop the engine and add coolant up to the proper
level if necessary .
• Reinstall the radiator cap.
• Check the level of coolant in the reserve tank and
fill to the correct level if the level is low.

6-3

COOLING SYSTEM

THERMOSTAT

RIGHT AIR CHAMBER COVER

REMOVAL
Remove the coolant drain plug and drain the
coolant (page 6-3).
Remove the right air chamber cover attaching screw
and the cover.

SCREW

Disconnect the wire from the temperawre sensor.
Remove the bolt that attaches the thermostat
housing to the air chamber.
Loosen the hose bands.
Remove the thermostat housing.

HOSE BANDS

Remove the thermostat housing cover.

6-4

"'

THERMOSTAT HOUSING

THERMOSTAT HO\SING COVER

COOLING SYSTEM

Remove the thermostat from the housing.

THERMOSTAT

HOUSING

INSPECTION
Inspect the thermostat visually for damage.
Suspend the thermostat in heated water to check its
operation.
Do not let the thermostat or thermometer touch
the pan or false readings will result.
Replace thermostat if valve stayes open at room
temperature, or if it responds at temperatures other
than those specified.

\

THERMOMETER

Technical Data
Start to open

80° to84°C (176°-183°F)

Valve lift

8 mm minimum (0.31 in)
when heated to 95°C (203°F)
for five minutes.

INSTALLATION

THERMOSTAT

Insert the thermostat into the housing.
Install a new O·ring on the thermostat housing
cover.
Install the thermostat housing cover and tighten
the bolts.

6-5

COOLING SYSTEM
TEMPERATURE SENSOR
IRE

Connect the housing to the hoses and tighten the
hose bands.
Secure the thermostat housing to the air chamber
with the bolt attaching the ground wire terminal
at the same time.
Connect the temperature sensor wire to the sensor.
Install the right air chamber cover.
Fill the cooling system (page 6·31.

I'\

RADIATOR/ COOLING FAN

THERMOSTAT HOUSING
AFTER '85:
'83, '84, '85:
RADIATOR GRILLE

REMOVAL
Remove the seat and raise the fuel tank after mak·
ing sure that the tank is less than half full.
Remove the drain plug and drain the coolant (page
6·3).
'83, '84, '85:
Loosen the radiator side cover attaching bolts and
nuts and remove the side covers and grill.
After '85:
Loosen the radiator side cover attaching nuts and
screws and remove the side cover and grill.

•

RADIA
SIDE COVER
FAN MOTOR COUPLER

Remove the left steering head cover attaching nut
and cover.
Disconnect the fan motor coupler.

NUT

6-6

COOLING SYSTEM
AFTER '85:

'83, '84, '85:

THERMOSTATIC

Disconnect the overflow tube at the radiator filler
neck.
Disconnect the thermostatic switch wires from the
switch.
Loosen the lower radiator hose band.

Loosen the upper radiator hose band.

LOWER
THERMOSTATIC
RADIATOR HOSE SWITCH WIRES
UPPER RADIATOR HOSE BAND

Remove the radiator mounting bolts.
Remove the radiator while pulling the upper and
lower hoses off.

DISASSEMBLY
Remove the four nuts attaching the fan shroud to
the radiator and remove the shroud.

RADIATOR

6-7

COO LING SYST EM

Remove the fan attaching nut and pull the fan off
the fan motor.

'83, '84, '85:
Remove the screws attaching the fan motor to the
fan shroud.
After '85:
Remove the nuts attaching the fan motor to the fan
shround.

RADIATOR

RADIATOR INSPECTION
Inspect the radiator soldered joints and seams for
leaks.
Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator,
wash them off with low pressure water.

6-8

COOLING SYSTEM

ASSEMBLY

COOLING FAN

NUT

Install the fan motor onto the fan shroud and
tighten the three screws.
Instal l the fan over the motor shaft.
Apply a locking agent to the fan motor shaft
threads, install and torque the plain washer, lock
washer and nut.

Install the fan shroud onto the radiator and tighten
the four nuts.

FAN SHROUD

INSTALLATION
Install the upper and lower hoses onto the radiator.
Install the radiator onto the frame and tighten the
mounting bolts.
Connect the upper and lower hoses and tighten the
hose bands.
Connect the wires to the thermostatic switch.
Connect the overflow tube to the filler neck.
Install the radiator grille and side covers.
Connect the fan motor coupler and install the left
steering head cover.
Fill the cooling system (page 6·3).
Install the fuel tank and seat.

RADIATOR MOUNTING BOLTS

6-9

COOLING SYSTEM

WATER PUMP

WATER PUMP

MECHANICAL SEAL INSPECTI ON
Remove the crankcase rear cover.
Inspect the telltale hole for signs of mechanical
seal coolant leakage.
Replace the water pump as an assembly if the
mechanical seal is leaking.

TELL TALE HOLE

REMOVAL

DRAI N BOLT

Remove the drain plug from the lower left frame
and drain the coolant .
Remove the drain bolt at the water pump and drain
the coolant from the cylinders.
Remove the gearshift arm and left footpeg bracket.

GEARSHIFT ARM

Disconnect the water hose from the water pump
cover.
Remove the water pump cover bolts and cover.

WATER HOSE

6-10

DRAIN BOLT

COOLING SYSTEM

Loosen the water hose bands.
Remove the water pump from the crankcase.

WATER PUMP

INSPECTION

0-RING

Check the water pump for mechanical seal leakage
and bearing deterioration.
Replace the water pump as an assembly if necessary.

I

~

~

WATER PUMP COVER

INSTALLATION
Apply a coat of clean engine oil to a new O·ring
and install it in the water pump groove.
Align the water pump shaft groove with the oil
pump shaft and insert the water pump into the
crankcase.

6-11

COOLING SYSTEM

Connect the water hose to the water pipe and the
water pump and tighten the hose bands.

WATER PIPE

WATER PUMP

Insert the dowel pins into the water pump, and
install a new 0-ring in the groove of the water pump
cover.
Install the water pump cover and torque the bolts.

Install the left foot peg bracket.
Align the punch marks on the gearshift arm and
the spindle, and install the gearshift arm.
Install the crankcase rear cover.
Tighten the drain plug at the left sub-frame.
Fill the system with a 50- 50 mixture of distilled
water and ethylene glycol (page 6-3).

GEARSH IFT ARM

6-12

CLUTCH

~
~

~a

4-7N·m
(0.4-0·7 kg ·m, 3-5 ft·lb)

~,

,~

..' .,,
25-35N·m

I

(2.5-3.5 k g·m, 18-25 ft·lb)

7-0

7.CLUTCH
SERVICE INFORMATION

7-2
7-3

TROUBLESHOOTING
CLUTCH FLUID REPLACEMENT/
AIR BLEEDING
CLUTCH MASTER CYLINDER
CLUTCH SLAVE CYLINDER

7- 11
7-11
7-13
7-18
7-22
7-24

CLUTCH COVER REMOVAL
STARTER CLUTCH DISASSEMBLY
CLUTCH DISASSEMBLY

7-4
7-6
7-8

CLUTCH ASSEMBLY
STARTER CLUTCH ASSEMBLY
CLUTCH COVER INSTALLATION

II

63- 67 N-m
(6.3-6.7 kg-m,
AFTER '85:

~rb)

~
~©fJ).

80-100 N·m
(8.0-10.0 kg-m,

,./

/

\~

..
..A

\ ./

.

AFTER '85:

0
0

7-1

CLUTCH

SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the clutch hydraulic system, clutch, and starter clutch.
• DOT4 brake fluid is used for the hydraulic clutch and is referred to as clutch fluid in the section. Do oot use other types
of fluid as they are not compatible.
• Clutch maintenance can be done with the engine in the frame.

SPECIFICATIONS
STANDARD
Clutch master cylinder
Clutch slave cylinder
Clutch

SERVICE LI MIT

Cylinder I.D.

16.870-15.913 mm (0.6248-0.6266 in)

16.93 mm (0.627 in)

Piston O.D.

16.827-16.854 mm (0.6231-0.6242 in)

15.80 mm (0.622 in)

Cylinder I.D.

38. 100-38.162 mm ( 1.5000-1.5024 in)

38.18 mm (1.503 in)

Piston O.D.

38.036-38.075 mm (1.4975-1.4990 in)

38.02 mm (1.497 in)

Outer guide I.D.

29.995-30.012 mm (1.1809-1.1816 in)

30.08 mm (1.184 in)

Spring free height

4.6 mm (0. 18 in)

3.6 mm (0.14 in)

Spring preload/length

115-135 kg/2 mm (254-298 lb/0.08 in)

Disc thickness

3.72-3.88 n1m (0. 147-0.153 in)

Plate warpage

-

3.1 mm (0.12 in)
0.30 mm (0.012 in)

Starter clutch

Driven gear O.D.

One way clutch

Clutch center 8 I.D.

74.50 mm (2.933 in)

Clutch inner O.D.

57.70 mm (2.271 in)

54.170-54.200 mm (2.1327-2.1339 in)

54.16 mm (2.132 in)

TORQUE VALUES
Clutch hose oil bolts
Clutch fluid reservoir cover '83:
After '83:
Starter clutch bolt
Clutch center lock nut
Starter clutch cover bolt
Master cylinder holder bolt

25-35 N·m (2.5- 3.5 kg-m, 18- 25 ft-lb)
2-3.5 N·m (0.2- 0.35 kg-m, 1.4- 2.5 ft-lb)
1- 2 N·m (0. 1- 0.2 kg-m, 0.7- 1.4 ft-lb)
80-100 N-m (8.0- 10.0 kg-m, 58-72 ft-lb)
63-67 N-m (6.3-6.7 kg-m, 46-48 ft·lb)
26- 30 N·m (2.6-3.0 kg·m, 19-22 ft-lb)
10-14 N·m (1.0-1.4 kg·m, 7-10 ft·lb)

TOOLS
Special
Snap ring pliers
Lock nut wrench

07914-3230001 -Equivalent tool commercially available.
079 16-4220000

Common
Universal holder
Driver
Attachment, 42 x 47 mm
Pilot, 36 mm

07725-0030000
07749-0010000
07746-0010300
077 46-0040800

7-2

CLUTCH

TROUBLESHOOTING
Clutch lever soft or spongy
1. Air bubbles in hydraulic system
2. Low fluid level
3. Hydraulic system leaking
Clutch lever too hard
1. Sticking piston(s)
2. Clogged hydraulic system
Clutch slips
1. Hydraulic system sticking
2. Discs worn
3. Springs weak

Motocycle creeps with clutch disengaged
1. Air bubbles in hydraulic system
2. Low fluid level
3. Hydraulic system leaking
4. Hydraulic system sticking
5. Plates warped
Excessive lever pressure
1. Hydraulic system sticking
2. Lifter mechanism damaged
Clutch operation feels rough
1. Outer drum slots rough
2. Sticking piston(s)

Clutch will not disengage
1. Air bubbles in hydraulic system
2. Low fluid level
3. Hydraulic system leaking
4. Hydraulic system sticking
5. Plates warped

7-3

CLUTCH

CLUTCH FLUID REPLACEMENT/
AIR BLEEDING

After '84 :

Check the fluid level with the fluid reservoir parallel
to the ground.

CAUTION:
Install the diaphragm on the reservoir when
operating the clutch lever. Failure to do so
will allow clutch fluid to squirt out of the
reservoir during clutch operation.
• Avoid spilling fluid on painted surfaces.
Place a rag over the fuel tank whenever
the system is serviced.
LOWER LEVEL MARK

BLEED VALVE

CLUTCH FLUID DRAINING
Connect a bleed hose to the bleed valve.
Loosen the slave cylinder bleed vlave and pump the
clutch lever.
Stop operating the lever when no fluid flows out of
the bleed valve.

CLUTCH FLUID FILLING
NOTE:
Do not mix different types of fluid since they
may not be compatible.
Close the bleed valve, fill the reservoir, and install
the diaphragm.
To prevent piston overtravel and clutch fluid seepage, keep a 20 mm (3/4 in) spacer between the
handlebar grip and lever when bleeding the clutch
system. Pump up the system pressure with the lever
until there are no air bubbles in the fluid flowing
out of the reservoir small hole and lever resistance is
felt. Then bleed the system.

7-4

CLUTCH
AIR BLEEDING
NOTE:
Check the fluid level often while bleeding
the clutch to prevent air from being
pumped into the system.
Use only DOT 4 brake fluid from a sealed
container.
• Do not mix brake fluid types and never
reuse the fluid which has been pumped out
during bleeding, or the efficiency of the
clutch system will be impaired.

1) Squeeze the clutch lever, open the bleed valve
1/2 turn then close the valve.
NOTE:
Do not release the clutch lever until the
bleed valve has been closed again.
2) Release the clutch lever slowly and wait several
seconds after it reaches the end of its travel.
Repeat the above steps until bubbles cease to appear
in the fluid coming out of the bleed valve.

Fill the fluid reservoir to a point somewhere between the upper and the lower levels.

LOWER LEVEL

7-5

CLUTCH

CLUTCH MASTER CYLINDER

OIL

DISASSEMBLY
Drain clutch fluid from the hydraulic system.
Remove the left rear view mirror and clutch lever.
Disconnect the clutch switch wires and remove
the clutch hose.

CAUTION:
A void spilling clutch fluid on painted surfaces.
Place a rag over the fuel tank whenever the
clutch system is serviced.
NOTE :
When removing the oil bolt, cover the end of
the hose to prevent contamination and secure
the hose.

Remove the master cylinder from the handlebar.
Remove the piston boot from the master cylinder.

PISTON BOOT

Remove the circlip from the master cylinder body.

SNAP RING PLIERS

07940-3230001

7- 6

LT

CLUTCH
After '84:

'83, '84:

Remove the piston and secondary cup.
Remove the primary cup and spring.
Remove the clutch switch, if necessary.

CLUTCH MASTER
CYLINDER

CLUTCH MASTE R
CYLINDER

~r

~

0

~

~-OJ

'A

\

PRIMARY CUP

PRIMARYCUP

.

SPRING/

/;:ISTON
r~

CLUTCH SECONDARY CUP
SWITCH

~LUTCH

~

SECONDARY
CUP

.:PRI.GJ2TON
CIRLP~f'

~

7

BOOT 7 j
PUSH ROD
PUSH ROD END PIECE

SWITCH

MASTER CYLIND ER 1.0. INSPECTION
Measure the master cylinder I.D.
Check the master cylinder for scores, scratches.
or nicks.
SERVICE LIMIT: 15.93 mm (0.627 in)

MASTER PISTON 0. 0 . I NSPECTION
Measure the master piston O.D.
SERVICE LIMIT: 15.80 mm (0.622 in)

Check the primary and secondary cups for damage
before assembly.

7-7

CLUTCH
ASSEMBLY

After '84:
f RESERVOIR COVER

'83, '84:

CAUTION :
Handle the master piston, spring, primary
cup, and secondary cup as a set.
Coat all parts with clean DOT-4 brake fluid before
assembly.
Install the spring, primary cup, and piston.

!.-6 /

RESERVOIR COVER

~

When installing the cups, do not allow the lips
to turn inside out.

DIAPHRG

~

~

~,

'-'',.._ -,--.- .

~:

~ ~T

MASTER
CYLINDER

w

~

J'
~

~

CLUTCH LEVER
P IVO

T

BOLT

Sl''
RING
ZPRIMARY CUP
PISTON AND

' ~

,

SECONDARY

COP

SWITCH

PUSH ROO END PIECE

, DIAPHRAGM

/MASTER

.
9

.. Qi
CLUTCH
SWITCH

~

Install thll oil hose with the bolt and its two sealing
washers.
Install the push rod end piece into the clutch lever
hole and install the clutch lever.
Connect the clutch switch w ires to the switch
terminals.
Fill the reservoir and bleed the clutch system
(page 7-4).
PUNCH MARK

Remove the left crankcase rear cover.

7-8

PRIMARY CUP

~

~

(. ~

-

IRCLIP

~

.

(]

· :,."

HOSE

TORQUE: 10-14 N·m (1.0-1.4 kg-m, 7- 10 ft-lb)

DISASSEMB LY

I

, PISTON AND
~
SECONDARY CUP

Place the master cylinder on the handlebar and
install the holder and the two mounting bolts.
Aligh the end of the holder with the punch mark on
the handlebar.
Tighten the top bolt first then the bottom bolt.

CLUTCH SLAVE CYLINDER

CYLINDER
HOLDER

#if!. • :' / /.

-~

PUSHROO .

CLUTCH

Install the circlip making sure it is seated firmly in
the groove.
Install the boot and push rod.
Install the clutch switch, if it was removed .

?'~

OLDER

-t..•

CAUTION:

,

~

CRANKCASE REAR COVER

CLUTCH
'83, '84, '85:
Remove the left crankcase rear cover bracket.
Place a container under the slave cylinder, remove
the oil bolt, and disconnect the clutch hose.
NOTE:

Avoid spilling clutch fluid on painted sur·
faces.
Remove the slave cylinder.

Remove the piston from the cylinder.
If the piston removal is hard, place a shop towel
over the piston to cushion t'he piston when it is
expelled, and position the cylinder with the piston
down.
Apply compressed air to the fluid inlet to remove
the piston. Use the air in short spurts.

Remove the spring from the slave cylinder.

SPRING

Remove the oil and piston seals.
Clean the piston groove with clutch fluid.
Check the piston spring for weakness or damage.

7-9

CLUTCH
PISTON 0.0. INSPECTION
Check the piston for scoring or scratches.
Measure the outside diameter of the piston with a
m icrometer.
SERVICE LIMIT: 38.02 mm (1.497 in)

CYLINDER 1.0. INSPECTION
Check the slave cylinder for scoring or scratches.
Measure the inside diameter of the cylinder bore.
SERVICE LIMIT: 38.18 mm (1.503 in)

ASSEMBLY

OIL SEAL

Assemble the slave cylinder in the reverse order of
disassembly. The oil seals must be replaced w ith
new ones whenever they have been removed.

AFTER '85 :

PISTON SEAL
PISTON

L~_·

Lubricate the piston and piston seal with a medium
grade of Hi-Temperature silicone grease or brake
fluid before assembly.
Be certain the piston seal is seated in the piston
groove.
Place the piston in the cylinder with the oil seal
end facing out.

SILICONE
GREASE

7-10

INSULLOR

r,

SLAVE CYLINDER BODY

-

a

-l

CLUTCH

Install the insulator and slave cylinder.
Connect the clutch hose with the oil bolt and the
two sealing washers.
Install the crankcase rear cover bracket.
Install the left crankcase rear cover.
Fill the clutch fluid reservoir with DOT-4 brake
fluid , and bleed the clutch system (page 7-4).

CRANKCASE REAR COVER
BRACKET
COVER

OIL BOLT

CLUTCH COVER REMOVAL
Drain the engine oil.
Remove the brake pedal and right footpeg.
Remove the clutch cover, gasket, and dowel pins.

BRAKE PEDAL

STARTER CLUTCH DISASSEMBLY
Remove the starter idle gear shaft and gear.

IDLE GEAR SHAFT

7-11

CLUTCH

Remove the alternator cover. Hold the flywheel
with a universal holder.

UNIVERSAL HOLDER OR FLYWHEEL HOLDER

07725-0030000
Remove the starter clutch bolt.
Remove the starter clutch assembly and spacer.

07725-0040000

STATER CLUTCH

0
STARTER CLUTCH BOLT
Shift the primary driven subgear with a screw·
driver to take preload off the primary drive gear
and remove the primary drive gear.

7-12

CLUTCH

Remove the starter driven gear and needle bearing
from the starter clutch .
Inspect the rollers for smooth operation.
Remove the starter clutch cover by removing
the three bolts.
Remove the clutch rollers, plungers, and springs.
Check the rollers for excessive wear.

STARTER DRIVEN GEAR
NEEDLE BEARING
STARTER CLUTCH

\

SPRING-.~

~(I>

I

~)-1(

~

g ()~
I

PLUNG~

STARTER CLUTCH COVER

~

\
OLLER

STARTER DRIVEN GEAR INSPECTION
Inspect the driven gear for damage or excessive
wear.
Measure the driven gear O.D.
SERVICE LIMIT: 54.16 mm (2. 132 in)

CLUTCH DISASSEMBLY
NOTE :
Do not operate the clutch lever after removing
the clutch . To do so will cause difficulty in
reassembling the clutch.
Remove the snap ring, lifter plate, lifter guide,
release bearing, and lifter rod.

LIFTER GUIDE

RELEASE BEARING

7-13

CLUTCH

Install the rear brake pedal.
Shift the transmission into high gear and apply the
rear brake.
NOTE:
When the engine is not in the frame, shift the
transmission into gear and use the MAINSHAFT HOLDER, P/ N 07923-6890100, to
hold the final shaft.
Remove the lock nut and lock washer.
Remove the clutch spring set plate, clutch spring,
and washer.

LOCK NUT WRENCH

079 16-4220000
Remove the clutch pressure plate.
Remove the clutch plates and discs.

CLUTCH CENTER B
Remove clutch center B and the one-way clutch as
an assembly.

ONE WAY CLUTCH

7-14

CLUTCH

Remove clutch center A and washer.

Remove the clutch outer and outer guide.

CLUTCH OUTER GUIDE

INSPECTION

NEEDLE BEARING

CLUTCH OUTER
Check the slots in the clutch outer for nicks, cuts,
or indentations made by the friction discs.
Check the clutch outer needle bearing for damage
or excessive play.
If the needle bearing is difficult to remove from the
clutch housing, use the following tools:
Driver: 07749-0010000
Attachment, 42 x 47 mm: 07746-0010300
Pilot, 35 mm: 07746-0040800

7-15

CLUTCH
CLUTCH OUTER GU IDE
Measure t he 1.0. of the clutch outer guide.

SERVICE LIMIT: 30.08 mm (1.184 in)

CLUTCH SPR ING
Measure the height of the clutch spring as shown.

SERVICE LIMIT: 3.6 mm (0.14 in)
Replace the spring if its height is less than the
service limit.

CL UTCH DISC
Replace the clutch discs if they show sings of scor·
ing or discoloration. Measure the thickness of each
disc.

SERVICE LIMIT : 3.1 mm (0.12 in)
Replace a ny discs that are thinner than the service
limit.

7-16

CLUTCH
CL UTCH PLAT E
Check the plate warpage on a surface plate, using
a feeler gauge.
SERVICE LIMIT: 0.30 mm (0.012 in)

ON E WAY CLUTCH INSPECTI ON
Inspect the one way clutch for smooth operation.
Check the rollers for excessive wea r.

Measure the 1.0 . of clutch center B.
SERVICE LIMIT: 74.50 mm (2.933 in)

7-17

CLUTCH

Measure the O.D. of the one way clutch inner.
SERVICE LIMIT: 57.70 mm (2.271 in)

OIL PUMP DRIVE SPROCKET

CLUTCH ASSEMBLY
Install the clutch outer guide over the mainshaft.
Install the needle bearing into the clutch outer.
Align the holes in the clutch outer with the pins
on the oil pump drive sprocket and install the clutch
outer over the guide.

Install clutch center A and the washer.

7-18

PINS

CLUTCH
FLANGED CAGE

Install the one-way clutch into clutch center 8 with
its flanged cage facing in.

Install the clutch inner into the one-way clutch by
turning it clockwise.

Install the one-way clutch/clutch center 8 assembly
over the mainshaft.
NOTE:

Make sure the one way clutch assembly is
installed correctly by turning the clutch
center B. The clutch center should turn
counterclockwise freely and should not turn
clockwise.

ONE-WAY CLUTCH

7-19

CLUTCH

Coat the discs and plates with clean engine oil.
Install the clutch discs and plates as shown.

CAUTION:
Do not pull clutch center Bout after installing
the discs and plates or a plate with fall between clutch centers A and B.
This will prevent the clutch from disengaging.

Install the clutch pressure plate.

Install the clutch spring set plate, clutch spring, and
washers.
NOTE:
Install the clutch spring with the dished face
towards the inside.
Install the lock washer with its "OUTSIDE" mark
facing out.
Install the lock nut.

WASHER

LOCK
WASHER

7-20

CLUTCH

Place the transmission in 6th gear.
Apply the brake and tighten the lock nut.
NOTE :
When servicing the clutch with the engine out
of the frame, shift the transmission into gear
and hold the output shaft with the HOLDER

07923- 6890101.
TORQUE : 63-67 N·m (6.3-6.7 kg-m, 46-48 ft-lb)

LOCK NUT WRENCH

07916-4220000
Install the clutch lifter rod.
Install the clutch filter plate, lifter guide, and bear·
ing.

LIFTER GUIDE

BEAR ING

LIFTER PLATE

Install the snap ring.

SNAP RING

7-21

CLUTCH

STARTER CLUTCH ASSEMBLY
Install the primary drive gear onto the crankshaft
while moving the primary driven subgear with a
screwdriver.

SCREWDRIVER

Install the thrust washer on the crankshaft.
Install the starter idler gear and shaft.

STARTER IDLER GEAR

Install the springs, plungers, and rollers into the
starter clutch.
Install the dowel pin.
Install the starter clutch cover aligning the dowel
pin hole with the dowel pin and tighten the bolts.
TORQUE : 26-30 N·m (2.6-3.0 kg-m, 19-22 ft-lb)
NOTE

I

Apply a locking agent to the bolt threads.

DOWEL PIN

7-22

CLUTCH COVER

CLUTCH

Install the starter driven gear by turning it counterclockwise.

STARTER D\EN GEAR

Align the punch marks on the starter clutch and
crankshaft and install the starter clutch.

Hold the flywheel with a universal holder and
tighten the starter clutch bolt to the specified
torque.
TORQUE : 80- 100 N·m
(8.0- 10.0 kg-m , 58-72 ft-lb)

Install the alternator cover.

7-23

CLUTCH

CLUTCH COVER INSTALLA liON
Install the dowel pins and a new gasket.

DOWEN PINS

Install the clutch cover.
Install the right footpeg and rear brake pedal.
Fill the crankcase with oil (page 2·3).

BRAKE PEDAL

7-24

RIGHT FOOTPEG

GEARSHIFT LINKAGE

AFTER '85:

8-0

8. GEARSHIFT LINKAGE
SERVICE INFORMATION

8- 1

TROUBLESHOOTING

8- 1

GEARSHI FT LINKAGE REMOVAL

8-2

GEARSHIFT LINKAGE INSTALLATION

8- 4

SERVICE INFORMATION
GENERAL
•
•

The gearshift spindle and stopper arms can be serviced with the engine in the frame.
If the shift forks, drum, and transmission require servicing, remove the engine and separate the crankcase.

TROUBLESHOOTING
Hard to shift
1. Air bubbles in the clutch hyd raulic system.
2. Shift forks bent
3. Shift claw bent
4. Shift drum cam grooves damaged
Transmission jumps out of gear
1. Gear dogs worn
2. Shift shaft bent
3. Shift d rum stopper broken
4. Shift forks bent

8-1

GEARSHIFT LINKAGE

GEARSHIFT LINKAGE REMOVAL
Drain the engine oil.
Remove the left crankcase rear cover.

Remove the left footpeg and gearshift pedal.
Remove the clutch cover and clutch assembly
(section 7).

GEARSHIFT PEDAL
OIL PUMP DR IVE CHAIN
Remove the oil pump driven sprocket bolt.
Remove the oil pump drive chain, drive and driven
sprockets.
Remove the oil pump drive sprocket washer.

OIL PUMP DRIVEN SPROCKET

8-2

BOLT

GEA RSHIFT LI NKAGE
DRUM STOPPER ARM

Remove the drum stopper arm nut, arm, and spring.

Pull the gearshift spindle assembly out of the crank·
case.

GEARSHIFT SPINDLE

Remove the neutral stopper arm bolt, arm, and
spring.

8-3

GEARSHI FT LI NKAGE

Remove t he shift drum cam plate bolt and cam
plate.

SHIFT DRUM CAM PLATE

GEARSHIFT LINKAGE INSTALLATION
Install the dowel pin in the hole of the shift drum.
Insert the five pins in the holes of the cam plate.
Align the cam plate hole with the dowel pin on the
shift drum and install the cam plate.
Tighten the bolt securely.

CAM PLATE

HOLE

PIN

Install the washer. neutral stopper arm. spring, and
arm bolt.
Tighten the arm bolt securely.

SPRING

8-4

ARM BOLT

GEA RSHIFT LINKAG E

Assemble the gearshift spindle and return spring and
install as shown.

RETURN SPRING

Install the washer, drum stopper arm, collar, spring,
washer,and nut over the arm bolt.
Tighten the nut securely.
Rotate the gearshift spindle and check the linkage
for smooth operation.

GEARSHIFT SPINDLE

DRUM STOPPER ARM

Install the oil pump drive sprocket washer on the
shaft.
Install the oil pump drive and driven sprockets
with drive chain and tighten the driven sprocket
bolt securely.
NOTE:
The driven sprocket has an "IN" mark that
must face the crankcase.
Install the clutch assembly and cover (section 7).

DRIVEN SPROCKET

BOLT

8-5

GEARSHIFT LINKAGE

Align the punch marks on the gearshift pedal and
gearshift spindle and install the gearshift pedal
assembly and left footpeg.
Install the left crankcase rear cover and fill the
crankcase with oil (page 2-3).

8-6

ALTERNATOR

80-100 N·m
_72 ft-lb)
(8.0-10.0 kg·m, 58

9-0

9. ALTERNATOR
SERVICE INFORMATION

9-1

FLYWHEEL REMOVAL

9-2

STATOR REMOVAL

9-3

STATOR INSTALLATION

9-3

FLYWHEEL INSTALLATION

9-4

SERVICE INFORMATION
GENERAL
•
•

This section covers removal and installation of the alternator.
Refer to section 18 for inspecting and troubleshooting.

TORQUE VALUE
Alternator rotor/Flywheel bolt

80- 100 N·m (8.0-10.0 kg-m, 58-72 ft·lb)

TOOLS
Common
Universal holder
Rotor puller

07725-0030000
07733-0020001 or 07933-3290001 (U.S.A. only)

9-1

ALTERNATOR

FLYWHEEL REMOVAL
Place a container under the alternator cover to catch
engine oil.
Remove the alternator cover.

Hold the flywheel with a universal holder and re·
move t he flywheel bolt.

Remove the flywheel with the rotor puller,
Remove the woodruff key from the crankshaft.

ROTOR PULLER
07933-3290001 U.S.A.) or 07733-0020001

UNIVERSAL HOLDER
07725-0030000

9-2

ALTERNATOR

STATOR REMOVAL

AFTER '84 :

Remove the seat and frame left side cover.
Disconnect the alternator coupler and remove the
wire bands.

ALTERNATOR COUPLER

Remove the left crankcase rear cover.
Remove the stator by removing the bolts and wire
clamp.

STATOR INSTALLATION
Install the stator and wire clamp.

AFTER '84:

Install the left crankcase rear cover.
Route the alternator leads according to the diagram
in Section 1 and connect the alternator wire coupler
to the wire harness.
Secure the alternator leads with the wire bands.
Install the seat and frame left side cover.

ALTERNATOR COUPLER

9-3

ALTERNATOR

FLYWHEEL INSTALLATION

UNIVERSAL HOLDER
07 25--00:3001)0

Install the woodruff key into the crankshaft.
Install the flywheel by aligning its keyway with the
key in the crankshaft.
Hold the flywheel with a universal holder and
torque the flywheel bolt.

TORQUE: 80-100 N·m
(8.0-10.0 kg-m, 58-72 ft-lb)

ALTERNATOR COVER
Install the alternator cover.
Check engine oil level and add oil if necessary (page
2-3).

9-4

CYLINDER HEAD/ VALVE
8 12 N·m
(0.8 1.2 kg-m 6 9 tt-l b)

I .

E4..

~
~

®

E4.~

®
®(/)

®®

18- 20 N·m
(1.8- 2 .0 kg·m, 13-14 ft·lb)

cf

~ ~®

/

48-52 N-m
(4.8 52
· kg-m, 35 38 f t·lb)

10-0

10. CYLINDER HEAD/VALVE
SERVICE INFORMATION

10- 1

VALVE GUIDE REPLACEMENT

TROUBLESHOOTING

10-2

VALVE SEAT INSPECTION/
REFACING

CAMSHAFT REMOVAL
CYLINDER HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY

10-3
10-7
10-'-9

10-13
10-14
1(}-15

CYLINDER HEAD ASSEMBLY
CYLINDER HEAD INSTALLATION
CAMSHAFT INSTALLATION

10- 16
10-19

SERVICE INFORMATION
GENERAL
•
•

The cylinder head can be removed with the engine in the frame.
If the cam sprockets of either front or rear cy linder are removed, the valve t iming of both cylinders must be checked during
reinstallation .
• Camshaft lubricating oil is fed through an oil line. Be sure the hole in the oil line is not clogged.
• During assembly, apply molybdenum disulfide to the camshaft holder surfaces to provide initial lubrication.
~
• The cylinder numbering is given below:

---

FRONT

SPECIFICATIONS
STANDARD
Camshaft

Cam height

35.335-35.495 mm (1.3911-1.3974 in)

35.3 mm

(1.39 in)

EX

35.335- 35.495 mm (1.3911-1.3974 in)

35.3 mm

(1.39 in}

-

0.10 mm

(0.004 in)
(0.012 in)

End clearance

Rocker arm
Valve

-

IN

Runout
Oil clearance

SERVICE LIMIT

13 ± 2 kg/cm 2 (184 ± 28 psi)

Compression pressure

0.05- 0.25 mm

(0.002- 0.010 in)

0.30 mm

Center

0.030-0.091 mm

(0.0012-0.0036 in)

0.095 mm (0.0037 in)

Both ends

0.030-0.091 mm

(0.0012-0.0036 in)

0.095 mm (0.0037 in)

Rocker arm I.D.

12.000- 12.018 mm (0.4724-0.4731 in)

12.05 mm (0.474 in)

Shaft O.D.

11.966-11 .984 mm (0.4711-0.47 18 in}

11.93 mm (0.470 in)

IN

5.475-5.490 mm

(0.2 156-0.2161 in)

5.47 mm

(0.215 in)

EX

5.455-5.470 mm

(0.2 148-0.2154 in)

5.45 mm

(0.214 in)

5.500-5.515 mm

(0.2165- 0.2171 i n)

5.55 mm

(0.219 in)

IN

0.010-0.040 mm

(0.0004- 0.0016 in)

0.08 mm

(0.003 in)

EX

0.030- 0.060 mm

(0.0012-0.0024 in)

0.10 mm

(0.004 in)

0.05 mm

(0.002 in)

86.55 mm (3.407 in)

Valve stem O.D.
Valve guide I .D.
Stem·to.guide clearance

-

Valve stem runout
Valve length
Valve seat width

IN

87.05 mm

(3.427 in)

EX

86.85 mm

(3.419 in)

86.35 mm (3.400 in)

1.2mm

(0.047 in)

1.5 mm

(0.06 in)

10-1

CYLINDER HEAD/ VALVE
Valve spring

Free length
Preload/length

Cylinder head

Inner

40.85 mm ( 1.608 in)

39.45 mm (1.553 in)

Outer

44.5 mm (1.752 in)

43. 1 mm ( 1.70 in)

Inner

6.67-7.83 kg/34.2 mm (14.70- 17.26
lb/1.35 in)

6.37 kg/34.2 mm
(14.04 lb/1.35 in)

Outer

13.7-16.1 kg/37.7 mm (30.20-35.49
lb/1.48 in)

3.0 kg/37.7 mm
(6.6 lb/1.48 in)

-

Warpage

0.05 mm (0.002 in)

TORQUE VALUES
Cylinder head cover
Camshaft holder (6 mm)
Cam chain guide A
Cyl inder head (10 mm)
Cylinder head (8 mm)
Rocker arm shaft
Cam sprocket

8-12 N·m (0.8-1.2 kg·m, 5.8-9.0 ft·lb)
10-14 N ·m (1.0-1.4kg-m, 7- 10ft·lb)
21-25 N·m (2.1-2.5 kg·m, 15-18 ft-lb)
48-52 N ·m (4.8-5.2 kg·m, 35-38 ft·lb)
21-25 N·m (2.1-2.5 kg·m, 15-18 ft·lb)
45- 50 N·m (4.5-5.0 kg-m, 33-36 ft·l b) Apply LOCKTITE® 271 to the threads
18-20 N-m (1.8-2.0 kg·m, 13- 14 ft-lb)

TOOLS
Special
Valve guide reamer, 5.5 mm
Valve guide driver
Valve guide driver attachment

07984-2000000
07942-3290100
07943- MB40000

Common
Valve spring compressor

07757-0010000

TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing
noises with a sounding rod or stethoscope.
Low compression
1. Valves
Incorrect valve adjustment
Burned or bent valves
Incorrect valve timing
Broken valve spring
2. Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head
3. Cylinder and piston (Refer to Section 12)

10-2

Compression t oo high
1. Excessive carbon build-up on piston or
combustion chamber
Excessive noise
1. Incorrect valve adjustment
2. Sticking valve or broken valve spring
3. Damaged or worn camshaft
4. Loose or worn cam chain
5. Worn or damaged cam chain tensioner
6. Worn cam sprocket teeth
7. Worn rocker arm and/or shaft

CYLINDER HEAD/ VALVE

CAMSHAFT REMOVAL

OIL DRAIN BOLT

FRONT CYLINDER

Drain the coolant (page 6·3) and engine oil from
the front cylinder head by removing the bolts and
washers.
'83-'85:
Remove the radiator (page 6-6).
After '85:
Remove the radiator (section 3).

COOLANT DRAIN BOLTS

Remove the cylinder head cover from the front
cylinder head.
Remove the cylinder head cover and cover base
from the rear cylinder head.

Remove the oil pipe and cam chain guide mounting
bolts and remove the cam chain guide.
Remove the alternator cover and rotate the crank·
shaft clockwise until the cam chain has free play.

REAR
CYLINDER
CAM CHAN GUIDE

Remove the oil pipe while pulling up on the middle
of the chain.
Remove the exhaust pipes (section 5).
Remove the carburetor (section 4).
Remove the engine mounting bolt on rear cylinder
head.

OIL PIPE

10-3

CYLINDER HEAD/ VALVE

Turn the crankshaft clockwise until the T1.3 mark
aligns with the rear crankcase mating surfaces.
Place rags or shop towels over the rear cylinder head
to prevent parts from being dropped into the crankcase.

INTAKE CAM SPROCKET

EXHAUST CAM SPROCKET

Remove the intake and exhaust cam sprocket bolts.
Turn the crankshaft clockwise one turn (360°) and
remove the other cam sprocket bolts.

CAMSHAFT HOLDERS

CAM CHAIN

Slide the cam sprockets with the cam chain off the
camshaft sprocket flanges.
Remove the cam chain from the sprockets and
remove the camshaft holders. Mark the camshaft
holders so that they can be reinstalled in thei r
original locations.

CAMSHAFT HOLDERS

10-4

CYLINDER HEAD/VALVE

Remove the camshaft holder dowel pins and the
intake and exhaust camshafts.

INTAKE CAMSHAFT

DOWEL PINS

Remove the cam sprockets from the camshafts.

CAMSHAFT/CAM HOLDER
INSPECTION

CAMSHAFT HOLDER

Inspect the camshaft and holder journal surfaces
for scoring, scratches, or evidence of insufficient
lubrication.

CAMSHAFT RUNOUT
Check camshaft runout with a dial indicator.
Support both ends of the camshaft with V·blocks.
SERVICE LIMIT: 0.10 mm (0.004 in)

10-5

CYLINDER HEAD/ VALVE
CAM INSPE CTION
Using a micrometer, measure each cam lobe.
SERVICE LIMITS: IN, EX : 35.3 mm (1 .39 in)

Check for wear or da mage.

Wipe any oil from the journals.
Lay a strip of plastigauge lengthwise on top of each
camshaft journal.

Install the camshaft holders and tighten in a
crisscross pattern.
NOTE:

Do not rotate the camshaft when using
plastigauge.
TORQUE:
A : 6mmBOLT: 10- 14N·m
(1.0-1.4 kg·m, 7- 10 ft-lb)
8 : 8 mm BOLT: 21 - 25 N-m
(2.1- 2.5 kg-m, 15- 18 ft-lb)
C: 10 mm BOLT: 48-52 N·m
(4.8- 5.2 kg-m, 35-38 ft-lb)

c

10-6

CYLINDER HEAD/ VALVE

Remove the camshaft holders and measure the
width of each plastigauge. The widest thickness
determines the oil clearance.
SERVICE LIMITS :
CENTER :
0 .095 mm (0 .0037 in)
BOTH ENDS: 0.095 mm (0.0037 in)
When the service limits are exceeded, replace
the camshaft and recheck the oil clearance.
Replace the cyl inder head and camshaft holders
if the clearance still exceeds service limits.

WATER HOSE

CYLINDER HEAD REMOVAL
Loosen the water hose clamp.
Remove the water pipes and hose.
Remove the water pipe O·rings.
Remove the oil pipe and sealing washers.

PIPES

OIL PIPE

Remove the f ront and rear cam chain tensioner
base mounting bolts.
Pull the cam chain tensioner base up.

10-7

CYLINDER HEAD/VALVE

Remove the slipper clip, washer, and pin and
remove the tensioner slipper base.

WASHER

Remove the cylinder head bolts
Remove the cylinder heads using a screw driver
at the pry points.

PRY POINT

Remove the front and rear cylinder head gaskets
and dowel pins.

10-8

TENSIONER BASE

CYLINDER HEAD/ VALVE

Remove the rear cylinder cam chain guide bolts
and guide.
NOTE:
When removing the front cylinder cam chain
guide, the crankcase must be separated.

CAM CHAIN GUIDE AND CAM
CHAIN TENSIONER INSPECTION

TENSIONER GU IDE

TENSIONER SLIPPER

Inspect the cam chain guide and tensioner for
damage or excessive wear.
Inspect the cam chain tensioner slipper for damage
or excessive wear.
Inspect the spring for good tension, and replace if
necessary.

CYLINDER HEAD DISASSEMBLY

ROCKER ARM

TENSIONER SPRING
ROCKER ARM
SHAFT BOLT

Remove the rocker arm shaft and rocker arms.
Remove the rocker arm spring and O·ring from
the shaft bolt.

ROCKER ARM
SHAFT BOLT

10-9

CYLINDER HEAD/ VALVE

Remove the valve spring cotters, retainers, springs
and valves.

CAUTION:
To prevent loss of tension, do not compress the valve springs more than necessary to remove the cotters.
• Position the large retainer on the compressor attachment, so the compressor will
not touch the cylinder head.
NOTE :
Mark all disassembled parts to ensure correct
reassembly.
Remove the valve stem seals.

Remove carbon deposits from the combustion
chamber and clean off the head gasket surfaces.
NOTE:
Avoid damaging the gasket surfaces.
Gaskets will come off easier if soaked in
solvent.

CYLINDER HEAD INSPECTION
Check the spark plug hole and valve areas for
cracks.
Check the cylinder head for warpage with a
straight edge and fee ler gauge.
SERVICE LIMIT: 0.05 mm (0.002 in)

10-10

VALVE SPRING COMPRESSOR
07757-0010000

CYLINDER HEAD/VALVE
ROCKER ARM INSPECTION
Inspect the rocker arms for wear or damage to
the camshaft contact surface or for a clogged oil
hole.
Measure the I .D. of each rocker arm.
SERVICE LIMIT: 12.05 mm (0.474 in)

ROCKER ARM SHAFT AND SPR ING
INSPECTION
Measure each rocker arm shaft O.D .
SERVICE LIMIT: 11.93 mm (0.470 in)
Inspect the shaft for wear or damage and calculate
the shaft to rocker arm clearance.
SERVICE LIMIT: 0.12 mm (0.005 in)
Inspect the rocker arm shaft spring for wear or
damage.

Measure the free length of the inner and outer valve
springs.
SERVICE LIMITS:
INNER (IN, EX):
OUTER (IN, EX):

39.45 mm (1.553 in)
43.1 mm (1.70 in)

10-11

CYLINDER HEAD/VALVE
VALVE STE M-TO-GUIDE
CLEARANCE
Inspect each valve for bending, burning, scratches,
or abnormal stem wear.
Check valve movement in the guide and measure
and record each valve stem 0.0.
SERVICE LIMITS: IN :

EX:

5.47 mm (0.215 in)
5.45 mm (0.214 in)

VALVE GUIDE REAMER

07984-2000000

NOTE:
Ream the guides to remove any carbon build·
up before checking clearances.
Measure and record each valve guide 1.0. using a
ball gauge or inside micrometer.
SERVICE LIMIT: 5.55 mm (0.219 in)
Subtract each valve stem 0.0. from the corres·
ponding guide 1.0. to obtain the stem to guide
clearance.
SERVICE LIMITS:

0.08 mm (0.003 in)
EX: 0.10 mm (0.004 in)

IN:

NOTE:
If the stem-to-guide clearance exceeds the
service limits, determine if a new guide with
standard dimensions would bring the clear·
ance within tolerance. If so, replace any
guides as necessary and ream to fit.
If the stem-to-guide clearance exceeds the service
limits with new guides, replace the valves also.
NOTE :
Reface the valve seats whenever the valve
guides are replaced (page 10·13).

10-12

CYLINDER HEAD/ VALVE
VALVE GU IDE DR IVER
07942-3290100

VALVE GUIDE REPLACEMENT
Heat the cylinder head to 100° C (212°F) with a
hot plate or oven.

CAUTION:
Do not use a torch to heat the cylinder;
it may cause warping.
To avoid burns, wear heavy gloves when
handling the heated cylinder head.
Support the cylinder head and drive out the old
guides from the combustion chamber side of the
cylinder head.

Adjust the tool setting depth by a pair of vernier
calipers .
DEPTH : 20.5 mm (0.81 in)
Drive new guides in from the rocker arm side of
the cylinder head.

VALVE GUIDE D RIVER

·-"=~

o7743-oo2ooooG

~

. c.....<:. . ..,t"3-~

DEPTH

"

~ -

NOTE:
Cylinder head heat should still be at 100°C
(212° F) for installation of the new guides.

VALVE GU I DE DRIVER
077 43-0020000

VAL VE GUID E RE A MER
07984-2000000

Let the cylinder head cool to room temperature
and ream the new valve guides.
NOTE:
• Use cutting oil on the reamer during this
operation.
Rotate the reamer in the same direction
when inserting and removing it.
Reface the valve seat (page 10·14) and clean the
cylinder head thoroughly to remove any metal
particles.

10-13

CYLINDER HEAD/ VALVE

VALVE SEAT INSPECTION /
REFACING
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of valve lapping compound
to each valve face. Lap each valve and seat using
a rubber hose or other hand -lapping tool.
NOTE:
Take care not to allow the compound to enter
between the valve stem and guide. After lapping, wash out the compound completely
and apply a coat of engine oil to the valve
face and seat.

Remove the valve and inspect the face.

CAUTION:
The valves cannot be ground. If the valve
face is rough, worn unevenly, or contacts the
seat improperly, the valve must be replaced.
lnseect the valve seat.
If the seat is too wide , too narrow, or has low spots,
the seat must be ground.

SEAT WIDTH:
0.99-1.27 mm
(0.039-0.050 in)

SERVICE LIMIT:
1.5 mm (0.06 in)

NOTE:
Follow the refacer manufacturer's operating
instructions.
After cutting the seat, apply lapping compound
to the valve face, and lap the valve using light
pressure.
After lapping, wash any residual compound off the
cylinder head and valve.
•

IN : CUTTER (30 mm</l)
EX: CUTTER (25 mm</J)

10-14

IN, EX: CUTTER (30 mm</l)

IN: CUT'TER (29 mm</l)
EX: CUTTER (24.5 mm</J)

CYLINDER HEAD/ VALVE

CYLINDER HEAD ASSEMBLY

RETAINER

NOTE:

Install new valve stem seals when assembling.
Use valve guide driver 07742-0010100.
Lubricate each valve stem with molybdenum
disulfide grease and insert the valve into the valve
guide. To avoid damage to the stem seal, turn the
valve slowly when inserting.
Install the valve springs and retainers. The springs
tightly wound coils should face toward the head.

VALVE COTTERS

Install the valve cotters.

CAUTION:

To prevent loss of tension, do not compress the valve spring more than necessary
to install the valve keepers.
Position the large retainer on the compressor attachment, so the compressor will not
touch the cylinder head.

VALVE SPRING COMPRESSOR
07757-0010000

Tap the valve stems gently with a soft hammer to
firmly seat the cotters.
NOTE:

I

Support the cylinder head above the work
bench surface to prevent possible valve
damage.
-

-

-~

10-15

CYLINDER HEAD/ VALVE

Install the 0-ring and spring onto the rocker arm
shaft.

ROCKER ARM
SHAFT BOLT

Apply LOCKTITE® 271 to the rocker arm bolt
threads.
Apply engine oil to the rocker arm shaft and install
the rocker arm.
Install and tighten the rocker arm shaft bolt.
TORQUE : 45- 50 N·m
(4.5-5.0 kg-m, 33-36 ft·lb)

0-RING

CYLINDER HEAD INSTALLATION
Clean the cylinder head surface of any gasket
material.

Instal l the dowe l pins and new head gaskets.
Install the rear cylinder cam chain guide.

DOWEL PINS

10-16

CYLINDER HEAD/ VALVE

Install the cylinder head and temporarily install the
cylinder head bolts.
NOTE :

Do not tighten the cylinder head bolts at this
time.

TENSIONER BASE

With the cam chain tensioner raised in the direction
of the arrow, insert a pin or piece of wire through
the hole in the tensioner base and tensioner.

HOLE

\

r
TENSIONER
TENSIONER BASE

Pass the cam chain through the cam chain tensioner
and install the tensioner slipper as shown.
NOTE:

Check that the lower end of the slipper fits
in the slipper base correctly.

TENSION ER SLIPPER

CLIP

PIN

10-17

CYLINDER HEAD/ VALVE

Install the exterior oil pipe with washers onto the
cylinder and cylinder head.

OIL PIPE

Install the water pipes and hose and tighten the hose
bands securely.

WATER HOSE

PIPES

10-18

OIL PIPE

CYLINDER HEAD/ VALVE

CAMSHAFT INSTALLATION
NOTE :
Follow this procedure from beginning to
end, even if you are only servicing one
cylinder head.
Check the camshaft marks so that you
install each camshaft in its correct location.
The marks on the camshaft mean :
EX RR (ER): Rear cylinder exhaust
IN R R (I R): Rear cylinder intake
EX F R (EF): Front cylinder exhaust
IN FR (IF): Front cylinder intake
The camshaft sprockets are interchangeable.

MARKS

/1
I

Rear Cylinder Head
Lubricate the cylinder head cam bearing surfaces
with molybdenum disulfide grease.

Turn the crankshaft clockwise until the Tl -3 mark
on the flywheel rotor aligns with the rear crankcase
mating surfaces.

CAUTION:
When turning the crankshaft, make sure the
cam chains don't jam at the cam chain tensioners or at the crankshaft.

-------------------------

10-19

CYLINDER HEAD/VALVE

Install the intake and exhaust camshafts and sprockets through the rear cylinder cam chain as shown.
Turn the camshafts so the camshaft marks face up.
NOTE:

If the front cylinder camshafts were not removed, check that the front camshaft marks
face up. If not, turn the crankshaft clockwise
360 degrees (one turn).
If a valve clearance adjuster keeps the camshaft
from seating fully in the cylinder head, back the
adjuster out all the way.

CAUTION:
If you force a valve open while installing the
camshaft holders, you may damage the
holders or the camshaft bearing surfaces.
Place the camshaft holders in the same locations
noted during removal. The groove in the bottom
of the holder must align with the camshaft locating
ridge.

CAMSHAFT HOLDERS

Install the camshaft holder bolts, but do not tighten
them yet.

10-20

CYLINDER HEAD/ VALVE

If the cylinders were not removed, lock the cam
chain tensioner for minimum tension: push the lock
plate down while pulling or prying the tension arm
up ; hold the arm up while you insert a pin or wire
through the lock holes.

Check that the camshaft marks are still facing up,
then al ign the sprocket index lines with the top of
the rear cylinder head. Place the cam chain on the
sprockets.

CAMS_!-iAFT MARKS

INDEX LINES

Slide the sprockets onto the camshaft flanges, and
install the sprocket bolts in the exposed holes.
Check that the sprocket index lines align at T1-3.
Unlock the cam chain tensioner.

10-21

CYLINDER HEAD/ VALVE
Front Cylinder Head
NOTE :
Install the rear cylinder head camshafts before
you install the front camshafts.
Lubricate the cylinder head cam bearing surfaces
with molybdenum disulfide grease .

Rotate the crankshaft counterclockwise 90 degrees
(1/4 turn). until the T2-4 mark aligns with the rear
crankcase mating surfaces.

CAUTION:
When turning the crankshaft, make sure the
cam chain doesn't jam at the cam chain
tensioner or at the crankshaft.
Install the Intake and exhaust camshafts and spro·
ckets. through the front cylinder cam chain as
shown.
Turn the camshafts so the camshaft marks face up.
Rotate each front camshaft counterclockwise 45
degrees (1/8 turn) to seat the cam fully in the
cylinder head.
If a valve adjuster keeps the camshaft from seating
fully in the cylinder head, back out the adjuster all
the way.
Install the front cylinder camshaft holders and
bolts, as described for the rear cylinder head.
Do not tighten at this time.
Lock the cam chain tensioner for minimum tension.

10-22

MARKS

INTAKE CAMSHAFT

CYLINDER HEAD/ VALVE
INDEX DOTS

Align the index dots on the front cylinder cam
sprockets with the top of the cylinder head (viewed
from the left side of the engine).
Place the cam chain on the sprockets.
Slide the sprockets onto the camshaft flanges, and
install the sprocket bolts in the exposed holes
(rotate the crankshaft clockwise a little if neces·
sary).
Check that the sprocket index dots align at T2·4.
Unlock the cam chain tensioner.

Front/Rear Cylinders
Check the front·to·rear cylinder camshaft timing
as follows.
NOTE:

INDEX PNES

• When the Tl -3 mark aligns with the rear
crankcase mating surface, the index lines
on all cam sprockets should align with the
top of the cylinder heads.
All camshaft marks will either face up or
down.
Turn the crankshaft as required to install the
remaining sprocket bolts at all four camshafts.
Tighten the camshaft sprocket bolts to the specified
torque.
TORQUE: 18-20 N·m (1.8-2.0 kg-m, 13- 14 ft·lb)

INDEX LINES

Tighten the tensioner base bolts securely.

TENSIONER BASE

10-23

CYLINDER HEAD/VALVE

Turn the crankshaft until there is maximum cam
chain free play, then install the oil pipes under the
cam chain.
Install the cam chain guide on the oil pipe base
plate.
Tighten the cylinder head 10 mm bolts in a criss·
cross pattern in 2-3 steps.
TORQUE: 48-52 N·m (4.8-5.2 kg-m, 35-38 ft-lb)
Tighten the cylinder head 8 mm bolts in a crisscross
pattern in 2-3 steps.
TORQUE: 21-25 N·m (2.1-2.5 kg-m, 15-18 ft-lb)
Tighten the cam shaft holder 6 mm bolts.
TORQUE: 10-14 N·m (1.0-1.4 kg-m, 7-10 ft-lb)

OIL PIPE

Lubricate the cam lobes with oil.

Adjust the valve clearance (page 3·9).

ARROW CASTING

Inspect the cylinder head cover gasket for damage
or deterioration.
NOTE:
Clean the gasket before applying sealant.
Apply sealant of the head cover gasket.
Install the front cylinder head cover and gasket.
Install the rear cylinder head cover base cover, and
gaskets. Be sure that the arrow casting on the rear
head cover faces the front of the engine.
Install the remaining parts in the reverse order of
removal.
HEAD COVER BASE

10-24

REAR HEAD COVER

CRANKCASE

,___ _

8mm

21-25
N·m
(2.1-2.5
kg-m, 15-18 ft-lb)

6mm

10- 14 N·m
7-10 ft-lb)
(1.0- 1.4 kg-m,

10mm

43-47
N-m
(4.3 4.7
k g-m, 31 34 ft·lb)

11-0

11. CRANKCASE
SERVICE INFORMATION

11-1

CRANKCASE DISASSEMBLY

11-2

CRANKCASE ASSEMBLY

11 -3

SERVICE INFORMATION
GENERAL
• To service the piston, crankshaft, connecting rod, and transmission, the crankcase halves must be separated.
• If a new crankcase is installed, perform countershaft shim selection procedures (page 13-17).
• The following parts must be removed before disassembling the crankcase.
Oil pan
Refer to section 2
Otl pump
Refer to section 2
Refer to section 6
Water pump
Clutch/starter clutch
Refer to section 7
Refer to section 8
Gear shift linkage
Refer to section 9
Alternator
Cylinder heads
Refer to section 10
Refer to section 21
Starter motor

Dl

TORQUE VALUES
10 mm bolt:
8 mm bolt:
6 mm bolt:

43- 47 N.m (4.3-4.7 kg-m, 31 - 34 ft-lb)
21-25 N·m (2.1 - 2.5 kg-m, 15-18 ft-lb)
10- 14 N·m (1.0-1.4 kg·m, 7- 10 ft-lb)

TOOLS
Special
Driver
Attachment

07949- 3710000
07946-371 0200

11-1

CRANKCASE

CRANKCASE DISASSEMBLY
Remove the upper crankcase bolts. Refer to Service
Information General (page 1 1-1) for removal of
necessary parts before disassembling crankcase.

MAINSHAFT BEARING HOLDER
Remove the mainshaft bearing holder by removing
the screw and bolts.

GEARSHIFT INDICATOR SWITCH
Remove the output gear case mounting bolts and
output gear case.
Measure the thickness of the output gear case
gasket and note it.
NOTE :
• Whenever removing the output gear case,
perform output gear case gasket selection,
if not measured right away.
• Index the bearing holder to the case for
ease of reinstallation.
Remove the gearshift indicator switch.

11-2

CRANKCASE

Turn the engine over and remove the lower crank·
case bolts.
NOTE:
Remove the bolts in two or more steps and
in a crisscross pattern to prevent damage to
the crankcase.
Separate the crankcase.
Remove the following parts :
• Piston and connecting rods (Section 12).
• Crankshaft (Section 12).
• Shift fork and shift drum (Section 13).
• Transmission (Section 13) .

Drive the countershaft !Jearing out of the case.

COUNTERSHAFT BEARING

CRANKCASE ASSEMBLY

ATTACHMENT
07946-3710200

Drive the countershaft bearing into the crankcase.

DR IVER
07949-37 10000

11-3

CRANKCASE

Install the following parts:
• Shift fork and shift drum (Section 13).
• Transmission (Section 13).
• Crankshaft (Section 12).
• Piston and connecting rods (Section 12).

Apply molybdenum disulfide grease to the shift
fork grooves of the M2, C5, and C6 gears.

C6 GEAR

11-4

C5 GEAR

CRANKCASE

Clean the crankcase mating surfaces.
Apply liquid sealant to the mating surface of the
lower and upper crankcase.

I

{

\

\

CAUTION:
Do not apply sealant to the area near the
main bearings.
DO NOT COAT THESE AREAS.

Install the dowel pin.

•\
I

Assemble the crankcase halves, aligning the shift
fork claws with the gears.
Tighten the bolts to the specified torque values in
the sequence shown.
TORQUE VALVES:
10 mm bolt: 43-47 N·m
(4.3-4.7 kg-m, 31-34 ft~b)
8 mm bolt: 21-25 N·m
(2.1-2.5 kg-m, 15-18 ft-lb)
6 mm bolt: 10-14 N·m
(1.0-1.4 kg-m, 7-10 ft-lb)

Tighten the bolts in a crisscross pattern and in 2-3
steps.

11-5

CRANKCASE
6 mm BOLT
Tighten the up~r
crankcase bolts to the specified
torque in a crisscross pattern and in 2-3 steps.
TORQUE: 8 mm: 21-25 N·m
(2.1-2.5 kg·m, 15-18 ft-lb)
6 mm: 10-14 N-m
(1.0-1.4 kg-m, 7-10 ft-lb)
Install the gearshift indicator switch.

8 mm BOLTS

MAINSHAFT BEARING HOLDEf!

Install the mainshaft bearing holder and tighten the
screw and bolts.

Install a new output gear case gasket with one of
the same thickness as removed.
NOTE:

6 mm BOLT

8 mm FLANGE BOLTS

Early production engines had gaskets that
were not marked.
The gasket is crushed 0.05 mm when the
output gear case is installed.
Install the output gear case with a new gasket.
Install the bolts and then tighten to the specified
torque.
TORQUES :
8 mm socket bolts:

21-25 N-m (2.1-2.5 kg-m, 15-18 ft-lb)

BOLTS

11-6

. CRANKSHAFT /PISTON

~

30- 34 N-m
{3.0- 3.4 kg-m, 22- 25 ft-lb)

•

12-0

FRONT

12. CRANKSHAFT / PISTON
SERVICE IN FORMATION

12-1

BEARING INSPECTION

12-8

TROUBLESHOOTI NG

12-2

BEA RING SE LECTION

12-10

CO NNECTING ROD REMOVAL

12-3

CRAN KSHA FT INSTAL LATI ON

12-12

PISTON REMOVA L

12-4

PISTON AND ROD INSTAL LA TI ON 12-12

CRANKSHAFT REMOVAL

12-7

SERVICE INFORMATION
GENERAL
•
•
•
•

All bearing inserts are select fit and are identified by color code. Select replacement bearings from the code tables. After
installing new bearings, recheck them with plastigauge to verify clearance.
Apply molybdenum disulfide grease to the main journals and crankpins during assembly.
Before removing the piston and connecting rod assemblies, clean the top of the cylinder off any carbon deposists.
For servicing the piston, connecting rod, and crankshaft, the crankcase assembly must be separated (Section 1 1).

SPECIFICATIONS
ITEM
Crankshaft

STANDARD

Connecting rod big end side clearance

-

Runout

Cylinder

Crankpin oil clearance

0.028- 0.052 mm

(0.0011-0.0020 in)

Main journal oil clearance

0.028- 0.052 mm

(0.0011-0.0020 in)

I. D.

79.500-79.515 mm (3.1299-3.1305 in)

--

-

Warpage
Piston

0.4mm

(0.02 in)

0.03 mm

(0.001 in)

0.07 mm

(0.003 in)

0.07 mm

(0.003 in)

79.60mm (3.134in)
0.05 mm

(0.002 in)

(0.0006-0.0018 in)

0.10mm

(0.004 in)
(0.004 in)

Ring-to-groove
clearance

Top
Second

0.015- 0.045 mm

(0.0006-0.0018 in)

0.10 mm

Ring end gap

Top

0.20- 0.35 mm

(0.008-o.014 in)

0.5mm

(0.02 in)

Second

0.20-0.35 mm

(0.008-o.014 in)

0.5mm

(0.02 in)

Oil (Side rail)

0.20- 0.70 mm

(0.008-0.028 in)

0.9mm

(0.04 in)

-Piston O.D .

0.015-0.045 mm

Piston-to-cylinder clearance

79.460- 79.490 mm (3.1283-3.1295 in)

79.35 mm (3.124 in)

O.Dl - 0.055 mm

0.10 mm

(0.0004-0.002 in)

(0.004 in)

Piston pin bore

20.002-20.008 mm (0.7875-o.7877 in) 20.06 mm (0.790 in)

Piston pin 0.0.

19.994- 20.000 mm (0.7872-o.7874 in)

19.98 mm (0.787 in)

Piston-to-piston pin clearance

0.002-0.014 mm

0.04 mm

Connecting rod small end 1.0.

20.016- 20.034 mm (0.7880-0.7887 in)

20.08 mm (0.791 in)

Piston pin-to-connecting rod clearance

0.016- 0.040 mm

0.060 mm (0.0024 in)

Length at 13 kg (29 lb) tension

361 .95-362.40 mm (14.250-14.269 in)

--

1--

Cam chain

(0.004-0.012 in)

0.10- 0.30 mm

SERVICE LIMIT

(0.0001 - 0.0006 in)
(0.0006- 0.0016 in)

(0.002 in)

364.9 mm (14.37 in)

TORQUE:
Connecting rod nut:
Crankcase
6 mm bolt:
8 mm bolt :
10 mm bolt:

30- 34 N·m
10-14 N·m
21-25N·m
43-47 N·m

(3.0-3.4 kg·m, 22-25 ft-lb)
(1.0-1.4 kg·m, 7- 10ft-lb)
(2.1 - 2.5kg·m,15-18ft-lb)
(4.3-4.7 kg-m, 31-34 ft-lb)

TOOL
Special
Piston Ring Compressor

Commercially available compressor (Auto'm otive style)

12-1

CRANKSHAFT /PISTON

TROUBLESHOOTING
Excessive noise
1. Crankshaft
• Worn main bearing
• Worn rod bearing
2. Piston and Connecting Rod
• Worn piston or cylinder
• Worn piston pin or pin hole
• Worn rod small end
low compression or uneven compression
1. Worn cylinder or piston ring
Excessive smoke
1. Worn cylinder, piston, or piston rings
2. Improperly instal led piston rings
3. Damaged piston or cylinder
Overheating
1. Excessive carbon build-up on piston head
2. Blocked or restricted flow of coolant
3. Sticking thermostat
Knocking or abnormal noise
1. Worn pistons and cylinders
2. Excessive carbon build-up on piston head.

12-2

CRANKSHAFT/PISTON

CONNECTING ROD REMOVAL
Separate the crankcase assembly (Section 11).
Check the connecting rod side clearance.
SERVICE LIMIT : 0.40 mm (0.016 in)

Remove the connecting rod bearing caps and note
their locations.

Push the connecting rods and pistons out through
the top of the cylinder bores.

CAUTI ON:
On engines with high mileage, inspect the
cylinders for a ridge just above the highest
point of ring travel. Any ridge must be removed with an automotive type ridge reamer
before removing the pistons to allow the
pistons and rings to pass through the cylinder.

12-3

CRANKSHAFT /PI STON

Mark the rods, pistons. bearings, and caps as you
remove them to indicate the correct cylinder and
position on the crankpins.

PISTON REMOVAL
Remove the piston pin clips. Push the piston pin
out and remove the piston.
Mark the piston pins to indicate their correct
piston posit ion.

PISTON/PISTON RING INSPECTION
Measure the piston ring·to-groove clearance.
SERVICE LIMIT : 0.10 mm (0.004 in)
(TOP/SECOND)

Remove the piston rings and mark them to. indicate
the correct cylinder and piston position.
Clean the piston crown, removing all carbon de·
posits.
Inspect the piston for cracks or other damage and
the ring grooves for excessive wear and carbon
build-up.

12-4

PISTON PIN CLIP

CRANKSHAFT/ PISTON

Using a piston, push the ring into the cylinder
squarely and measure the end gap.
SERVICE LIMITS:
TOP:
SECOND:
01 L (Side rail):

0.5 mm (0.02 in)
0.5 mm (0.02 in)
0.9 mm (0.04 in)

Measure the piston O.D.

T ake measurements 10 mm (0.4 in) from the
bottom, and 90° to the piston pin hole.
SERVICE LIMIT: 79.35 mm (3.124 in)

Inspect the cylinder bores for wear or damage.
Measure the cylinder 1.0. at three levels in X andY
axis.
SERVICE LIMIT: 79.60 mm (3.134 in)
Calculate the piston·to·cylinder clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)
Oversize pistons are available in the following sizes:
0.25, 0.50, 0.75 and 1.00 mm.

12-5

CRANKSHAFT/PISTON

Measure each piston pin hole 1.0 .
SERVICE LIMIT: 20.06 mm (0.790 in)

Measure each piston pin 0.0.
SERVICE LIMIT: 19.98 mm (0.787 in)
Calculate the piston pin to piston clearance.
SERVICE LIMIT: 0.04 mm (0.002 in)

Measure the connecting rod small end 1.0. If the
reading exceeds the service limit, replace the rod.
SERVICE LIMIT: 20.08 mm (0.791 in)

12-6

CRANKSHAFT/PISTON

CRANKSHAFT REMOVAL

CAM CHAIN
(REA R CY LINDE R)

CRAN KS HAFT

Remove the crankshaft.
Remove the cam chain .

CRANKSHA FT INSPECTION

~

Set the crankshaft on a stand or blocks.
Set a dial indicator on the center main bearing
journal. Rotate the crankshaft two revolutions and
read the runout.
S ERVICE LIMIT: 0 .03 mm (0.001 in )

CA M CHAI N L ENGTH MEASU REMENT
Place the cam chain on the camshaft sprockets
with the punch' marks positioned as indicated.
Secure one camshaft sprocket and apply 13 kg
(29 lbs) of tension to the other.
Then measure the distance between the punch
marks as shown .
SERVICE LIMIT: 364.9 mm (14.37 in)
NOTE :
The punch marks should be parallel to each
other.
Replace the cam chain if it is longer tha n the service
limit.

12-7

CRANKSHAFT/ PISTON

BEARING INSPECTION
CONNECTING RODS
Inspect the bearing inserts for damage or separation.
Clean all oil from the bearing inserts and crankpins.
Put a piece of plastigauge on each crankpin avoiding
the oil hole.

CAUT ION:
The bearing tabs should face toward the
exhaust ports. Remember the front and rear
cylinder exhaust ports face opposite directions.

Install the bearing caps and rods on the correct
crank pins, and tighten them evenly.
TORQUE: 30-34 N·m (3.0-3.4 kg·m, 22-25 ft-lb)
NOTE:

Do not rotate the crankshaft during inspection.

Remove the caps and measure the compressed
plastigauge on each crankpin.
OI L CLEARANCE SERVICE LIMIT:
0.07 mm (0.003 in)

12-8

CRANKSHAFT/ PISTON
MAIN BEARINGS
Inspect the bearing inserts for damage or separation.
Clean all oil from the bearing inserts and journals.
Put a piece of plastigauge on each journal, avoiding
the oil holes.

PLASTIGAUGE

Install the main bearings on the correct journals
on the lower crankcase and tighten them evenly
in 2-3 steps in the sequence shown.
TORQUE VALUES:

6 mm bolt: 10- 14 N·m
(1.0- 1.4 kg·m, 7-10 ft-lb)
8 mm bolt: 21 -25 N-m
(2.1-2.5 kg-m, 15- 18 ft-lb)
10 mm bolt: 43-47 N-m
(4.3-4.7 kg-m, 31-34 ft·lb)
NOTE:
Do not rotate the crankshaft during inspec·
tion.

Remove the lower crankcase and measure the com·
pressed plastigauge on each journal.
OIL CLEARANCE SERVICE LIMIT :

0.07 mm (0.003 in)

12-9

CRANKSHA FT/ PISTON

BEARING SELECTION
If rod bearing clearance is beyond tolerance, select
replacement bearings as follows:

CONNECTING ROD BEARING
INSERTS
Determ1ne and record the corresponding rod I.D.
code number.
NOTE :
-

~

The number 1 or 2 on each connecting rod is
the code for each connecting rod I.D.

I.D.CODE

Determine and record the corresponding crankpin
O.D. code number (or measure the crankpin O.D .).
NOTE :
The letters A or B on each crank weight is the
code for each crankpin O.D .

O.D. CODES

Cross reference the crankpin and rod codes to determine the replacement bearing color.
CRANKPIN 0.0. CODE NO.
A

8

39.99240.000mm

39.98439.992mm

I--

-..:.o

.
oo
o
w .z

1

43.00043.008mm

C (Yellow)

8 (Green)

z<.:l....:o
oz 0 2
o- 0

43.00843.016 mm

B (Green)

A (Brown)

zO::Ow

BEAR ING INSERT THICKNESS:
A (Brown): 1.494-1.498 mm (0.0588-0.0590 in)
B (Green): 1.490-1.494 mm (0.0587-0.0588 in)
C (Yellow): 1.486-1.490 mm (0.0585- 0.0587 in)
COLOR CODE

12-10

CRANKSHAFT/PISTON
MAIN BEARING
Determine and record crankcase I.D. code numbers.
NOTE:
The letters (I or II) on the upper rear crankcase shown are the codes for the main journal
I.D. from left to right.

Determine and record the corresponding main
journal O.D. code numbers (or measure the main
journal O.D.).
NOTE:
A number 1 or 2 on each crank weight is
the code for the adjacent main journal O.D.

Cross reference the case and journal codes to determine the replacement bearing.
MAIN JOURNAL 0.0.
CODE NO.

cici
_:;z
<{Q

2

39.99240.000 mm

39.98439.992mm

I

43.00043.008 mm

C (Yellow)

B (Green)

II

43.00843.016 mm

B (Green)

A (Brown)

ww
(I)U

uu

1

MAIN BEARING INSERT THICKNESS:
A (Brown): 1.498-1.502 mm (0.0590-0.0591 in)
B (Green): 1.494-1.498 mm (0.0588-0.0590 in)
C (Yellow): 1.490-1.494 mm (0.0587-0.0588 in)

COLOR CODE

12-11

CRANKSHA FT /PI STON

CRANKSHAFT INSTALLATION
Install the main bearings into the upper crankcase.
Apply molybdenum disulfide grease to the upper
and lower main bearings.
Install the crankshaft w ith the cam chain.

PISTON AND ROD INSTALLATION
Clean the piston domes, ring lands, and skirts.
Carefully install the piston rings onto the piston.
Stagger the ring end gaps as shown.

NOTE :
Be careful not to damage the piston and
piston rings during assembly.
All rings should be installed with the
markings facing up.
After installing the rings they should rotate
freely, without sticking.

20mm0R MOR£

12-12

GAP

CRAN KSHA FT/ PI STON
"MB4-F" MARK

FRONT CYLINDER
Coat the rod small end with molybdenum disulfide
grease.
Assemble the pistons and connecting rods with the
pistons and piston clips as follows.
Front cylinder connecting rod and piston assembly.
Note that the front cylinder connecting rods are
marked MB4-F.
Install the pistons on the front connecting rods so
that the intake "IN" mark is facing opposite the oil
hole in the rod.

OIL HOLE

"IN" MARK
REAR CYLINDER

"MB4·R" MARK

Rear cylinder connecting rod and piston assembly.
Note that the rear cylinder connecting rods are
marked MB4-R.
Install the pistons on the rear rods so that the intake
"IN" mark is facing the same direction as the oil
hole in the rod.
NOTE:
Do not interchange the pistons, piston
pins, or connecting rods.
Make sure that the p1ston pin clips are
properly seated.

OIL

OLE

"IN" MARK

Align the hole in the connecting rod bearing insert
with the hole in the connecting rod and instal l the
insert.

OIL HOLES

12-13

CRANKSHAFT/ PISTON

Install the connecting rod cap bearing insert.
Apply molygdenum disulfide grease to the connect·
ing rod bearings.

CONNECTING ROD BEARINGS

Coat the cylinders, piston rings/grooves, and pistons
with oil.
Install the rod and piston assemblies into the
cylinders from the top of the crankcase. Be sure
each assembly is returned to its original position as
noted during removal.

"IN" MARKS

NOTE:
The piston intake " IN" marks should be
facing each other as shown.

PISTON RING COMPRESSOR
(Commercially available)
Compress the piston rings with a ring compressor
and insert the piston and rod into ttre cylinder.
NOTE :
Be careful not to damage the pistons or
rings during assembly.
To prevent damage to the crankpin jour·
nals, slip short sections of rubber hose over
the rod bolts before installation .

__

.__

12-14

CRANKSHAFT/PISTON

Install and torque the connecting rod nuts.
TORQUE: 30-34 N·m (3.0-3.4 kg-m, 22-25 ft-lb)
NOTE:
Be sure the bearing caps are installed in
their correct location as marked during
removal.
• Tighten the nuts in two or more steps.
After tightening the bolts, check that the
rods move freely without binding.
Assemble the crankcase (See page 11 ·3).

12-15

TRANSMISSION

13-0

13. TRANSMISSION
SERVICE INFORMATION
TRANSMISSION DISASSEMBLY

13- 1
13- 2
13-3

OUTPUT DRIVEN GEAR
REMOVAL

13- 9

GEAR TOOTH CONTACT
PATTERN CHECK

13- 14

TROUBLESHOOTING

COUNTERSHAFT INSPECTION
SHIFT FORK AND SHIFT DRUM
TRANSMISSION ASSEMB LY
COUNTERSHAFT

13-17
13-18
13-21
13-22

SERVICE INFORMATION
GENERAL
•
•
•
•

The gearshaft linkage can be serviced with the engine in the frame (Section 8) .
For mternal transmission repairs, the crankcase must be separated (Section 11 ).
Replace the countershaft and output driven gear as a set.
When using the lock nut wrench, use a deflecting beam type torque wrench 14·20 inches long. The lock nut wrench in·
creases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock
nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench when used
with the lock nut wrench. The torque wrench scale reading is given with the actual torque specification.

SPECIFICATIONS
STANDARD

!-

Transmission

Backlash

low

0.089- 0.179 mm

(0.0035-0.0070 in)

2nd, 3rd, 4th, 5th, 6th

0.068-0.136 mm

(0.0027- 0.0054 in)

0.18 mm (0.007 in)

Gear I.D.

M5, M6, C2, C3, C4

31.000-31.0 1G mm (1.2205-1.22 11 in)

31 .18 mm (1.228 in)

Gear bushing
O.D.

M5, MG. C2, C3, C4

30.950- 30.975 mm (1.2185- 1.2195 in)

30.93 mm (1.218 in)

Gear bushing
I.D .

M5, C4

27 .995- 28.016 mm (1.1022-1.1030 in)

28.05 mm ( 1. 104 in)

Mainshaft O.D.

at MS

27.977- 27.990 mm ( 1.1015-1.1020 in)

27.92 mm (1.099 in)

at C4

27.977- 27.990 mm (1 . 1015- 1.1020 in)

27.92 mm (1.099 in)

0.025- 0.0GG mm

(0.0010-0.002G in)

0.10 mm (0.004 in)

0.005- 0.039 mm

(0.0002- 0.0015 in)

0.05 mm (0.002 in)

G.43-6.50 mm

(0.253-Q.256 in)

G. 1 mm

--1-

Countershaft
O.D.

Shift fork

Gear·to·bushing M5, MG. C2, C3, C4
or shaft
gear·to·bushing
clearance
M5, C4 bushing·to·
shaft
Claw thickness
I. D .

Fork shaft

SERVICE LIMIT
0.24 mm (0.009 in)

O.D.

~'85

: Left and r ight 14.000- 14.018 mm (0.55 11 - 0.5519 in)
er '85: Left and right 14.01G- 14.034 mm (0.5511 - 0.5525 in)
13.9G6-13.984 mm (0.549-0.550 in)

(0.24 in)

14.05 mm (0.553 in)
14.07 mm (0.554 in)
13.90 mm (0.547 in)

13-1

TRANSM ISSION

TORQUE VALUES :
Output gear case bearing holder
Output gear case 8 mm socket bolt
Output gear bearing lock nut (outer)
(inner)
Sh ift fork center

30- 34 N.m (3.0-3.4 kg-m, 22-25 ft·lb)
21-25 N·m (2.1-2.5 kg·m, 15-18ft-lb)
90-110 N.m (9.0-11 .0 kg-m, 65-80 ft·fb)
70-80 N.m (7.0-8.0 kg-m, 5 1- 58 ft-lb)
16- 20 N ·m ( 1.6-2.0 kg-m, 12- 14 ft-lb)

TOOLS:
Special
Lock nut wrench, 30/64 mm
Lock nut wrench, 42/56 mm
Shaft hold er
Bear ing remover, 17 mm
Remover hand le
Remover weight

07916- MBOOOOO
07916- MB40000
07923- 6890101
07936-371 0300t
07936- 371 0100 or Bearing remover set 07936-37 10000
07936-371 0200

Common
Driver
Pilot, 30 mm
Pilot, 35 mm
Attachment, 62 x 68 mm
Attachment, 52 x 55 mm
Attachment, 42 x 47 mm
Pilot, 17 mm
Driver
Att achment, 30 mm

07749-0010000
077 46- 0040700
07746- 0040800
07746-0010500
077 46- 001 0400
077 46- 001 0300
077 46-0040400
077 42-00301 00
077 46-0030300

or Driver 07949- 6110000

TROUBLESHOOTING
Hard to shift
1. Clut ch slave cylinder sticking
2. Shift fork bent
3. Shift shaft bent
4. Shift claw bent
5. Shift drum cam grooves damaged

13-2

Transmission jumps out of gear
1. Gear dogs worn
2. Shift shaft bent
3. Shift drum stopper broken
4. Shift forks bent

TRANSMISSION

For servicing of the gearshift linkage, see Section 8.

TRANSMISSION DISASSEMBLY
Separate the crankcase (Section 11 ).
Remove the dowel pin from the crankcase.
Inspect the backlash of each gear.
SERVICE LIMITS:
Low:
0 .24 mm (0.009 in)
2nd, 3rd, 4th, 5th, 6th: 0 .18 mm (0.007 in)
Remove the mainshaft and countershaft.
Remove the output gear case.

MAINSHAFT
Index the countershaft bearing holder to the output
gear case, for ease of reassembly.
NOTE:
When removing the countershaft, pull the
countershaft with remaining gears out of
crankcase after removing the C1, C5, C2, C3
gears, spline washer, plain washers, and bush·
ings in the crankcase.

l
C3 GEAR

C5 GEAR

13-3

TRANSMISSION

TRANSM ISSION INSPE CTI ON

I. D.

Check gear dogs, dog holes, and teeth for excessive
or abnormal wear, or evidence of insufficient
lubrication.
Measure the I.D. of each gear.

SERVICE LIMITS :
MS, M6, C2, C3, C4 gear: 31 .18 mm (1 .228 in)

Measure t he I. D. and O.D. of the gear bushings.

SERVICE LIMITS :
MS, M6, C2, C3, C4 gear bushing 0 . 0 . :
30.93 mm (1 .218 in)
MS, C4 gear bushing I. D.:
28.05 mm (1 .104 in)

I. D.

O.D.

Measure the O.D. of t he mainshaft and countershaft.

SERVICE LIMITS:
A (at MS bushing): 27.92 mm (1 .099 in)
B (at C4 bushing): 27.92 mm (1.099 in)

Calculate the clearance between t he gear and gear
shaft or bushing.

SERVICE LIMITS :
MS, M6, C2, C3, C4 gear-to-bushing:
0.10 mm (0.004 in)
MS, C4 gear bushing-to-shaft:
0.05 mm (0.002 in)

13-4

TRA NSMISSION
DRIVE GEAR REMOVAL

DOWEL PI N

Remove the dowel pin and 0-rings.

0-RINGS

Place the output gear case in a vise with soft jaws,
being careful not to distort the case.

OUTPUT GEAR CASE

Place the shaft holder tool on the output driven gear
shaft, wedging it against the vise to lock the shaft.
Unstake the inner bearing race lock nut with a '!rill
or grinder. Be careful that metal particles do not
enter the bearing and that the threads on the shaft
are not damaged.

Remove the inner bearing race lock nut.
Discard the nuts.

SHAFT HOLDER

LOCK NUT WRENCH, 42/56 mm

07923-6890101

07916-MB40000

\

COUNTERSHAFT

13-5

TRANSMISSION

Remove the countershaft bearing holder bolts and
holder from the case.
Remove the output drive gear and shim.

Place the countershaft/holder in a press.
Press the countershaft out of the bearing holder.

COUNTERSHAFT BEARING
REPLACEMENT
NOTE :
The oountershaft must be removed before
replacing bearing.
Place the bearing holder in a vise with soft jaws
or shop towel.
NOTE:
Do not damage the bearing holder, especially
the crankcase mating surface.
Unstake the outer race lock nut with a punch.
Remove the bearing outer race lock nut with a
special tool. Discard the lock nut.

13-6

,,

TRANSMISSION
Place the bearing holder in a press and remove the
bearing.

ATTACHMENT, 62 x 68 mm

DRIVER

07746-0010500

077 49- 001 0000

Press in a new bearing.

PILOT, 35mm

07746-0040800

Place the bearing holder in a vise with soft jaws
and install and tighten a new outer race lock nut
to the specified torque value.
TORQUE: 90-110 N·m
(9.0-11.0 kg-m, 65-80 ft-lb)

LOCK NUT WRENCH,

42/56 mm
07916-MB40000

Torque wrench scale reading:
80.:..100 N·m (8.0-10.0 kg·m, 58-73 ft·lb)
Stake the new lock nut.

COUNTERSHAFTINSTALLATION
NOTE:
The countershaft and driven gear must be
replaced as a set if they or the gear case or
the bearing require replacement.
Place the countershaft and countershaft bearing
holder into a press. Press the countershaft into the
bearing.
NOTE:
Place the threaded end of the pilot into the
countershaft.
Place the adjustment shim over the bearing holder.
NOTE:
If the countershaft/driven gear, bearing or
gear case are replaced, a new adjustment shim
must be selected (page 13·15, Backlash
Inspection).

BEARING HOLDER

13-7

TRANSMISSION

Place the countershaft/bearing holder and correct
adjusting shim into the output gear case.
Install the bolts and sealing washers with the cover
bracket.
Tighten the bolts in a crisscross pattern until the
drive gear bearing holder seats against the case.
Then tighten to the specified torque.
TORQUE: 30-34 N·m (3.0-3.4 kg·m, 22-25 ft·lb)

Place the case into a vise with soft jaws.

LOCK NUT WRENCH,
42/56 mm

Install and tighten a new countershaft nut to the
spec1fied torque.

07916-MB40000

TORQUE: 70-80 N·m (7.0-8.0 kg·m , 51 - 58 ft-lb)
Torque wrench scale reading:
64-73 N·m (6.4-7.3 kg·m, 46-53 ft·lb)

Stake the lock nut.

13-8

TRANSMISSION

OUTPUT DRIVEN GEAR REMOVAL

OIL SEAL

Remove the output driven gear oil seal from the
output gear case.
Place the output gear case into a vise, clamping it at
the shift shaft spindle boss.

LOCK NUT WRENCH, 30/64 mm
Unstake and loosen the output driven gear bearing
inner race lock nut using a special lock nut wrench
and shaft holder.

07916- MBOOOOO

DRIVEN GEAR
BEAR ING HOLDER

Remove the driven gear bearing holder mounting
bolts and remove the gear and holder from the case.

BEARING OUTER RACE
HOLDER

13-9

TRANSMISSION
0-RING

BEARING HOLDER

Remove the shim and 0-ring from the bearing
holder.

SHIM

OUTPUT DRIVEN GEAR BEARING
REPLACEMENT
Place the output driven gear bearing holder into a
vise with soft jaws. Unstake and remove the output
driven gear bearing outer race lock nut from the
holder.
Press the output driven gear from the holder.

Place the bearing holder in a press and press the
bearing out.

DRIVER

07749-0010000

NOTE :
Be careful not to damage the bearing holder
gear case mating surface.

PILOT, 30 mm
077 46-0040700

13-10

TRANSMISSION

Press in a new bearing and make sure it rotates
freely.

DRIVER

07749- 0010000

Place the bearing holder into a vise with soft jaws.
Install and tighten a new bearing outer race lock
nut to the specified torque value.

ATTACHMENT 52 x 55 mm

PILOT, 30 mm

07746-0010400

07746-0040700

LOCK NUT WRENCH

30/64 mm
07916- MBOOOOO

TORQUE: 90-110 N·m
(9.0-11.0 kg-m, 65-80 ft-lb)
Torque wrench scale reading:
80-100 N·m (8.0-10.0 kg-m, 58-72 ft-lb)

OUTPUT DRIVEN GEAR
INSTALLATION
NOTE:
When the gear set, driven gear bearing and/
or gear case have been replaced, use a shim
0.30 mm (0.012 in) thick for initial reference.
Place the output driven gear bearing holder into a
press.
Then press in the output driven gear.
Install the 0-ring and correct shim. See page 13-14
for shim selection procedure.

13-11

TRANSM ISSION

Attach the bearing holder onto the gear case with
the four hex bolts. Tighten the bolts in a crisscross
pattern in two or more steps.
TORQUE: 30-34 N·m (3.0-3.4 kg-m, 22-25 ft-lb)

Install a new bearing inner race lock nut and tighten
it to the specified torque.
TORQUE: 70-80 N-m (7.0-8.0 kg-m, 51-58 ft-lb)

BEARING INNER RACE
LOCK NUT

Torque wrench scale reading:
64-73 N-m (6.4-7.3 kg-m, 46-53 ft-lb)

STAKE
Stake both new lock nuts and install a new oil seal.

STAKE

13-12

OIL SEAL

TRANSMISSION
OUTPUT DRIVEN GEAR CASE
BEARING REPLACEMENT
Heat the output gear case around the bearing to
80°C (176° F) .

CAUT ION:
y-s- w-ea_r_g_l-ov_e_s_w_h_e_n_h_a_n_d_lin_g_ a_h_e-at_e_d-.,

case.

------------------

BEARING REMOVER, 17 mm
10300

Remove the bearing with the bearing remover.

HANDLE
07936- 3710100
DRIVER 07749-0010000

Drive a new bearing into the output gear case.

'
ATTACHMENT, 42 x 47 mm
077 46- 001 0300

l.

''

PILCh, 17 mm
077 46- 0040400

13-13

T RANSMISSION

GEAR TOOTH CONTACT PATTERN
CHECK
Remove the drive and driven gears (pages 13-5 and
13-9).
Apply Prussian Blue to the driven gear teeth.
Install the drive and driven gears with the standard
shims.
Rotate the drive gear several times in the normal
direction of rotation.
Check the gear tooth contact pattern after removing
the drive gear.

Contact is normal if Prussian Blue in transfered
to the approximate center of each tooth and slightly
to the side.

SH IMS
COUNTERSHAFT

FACE .
FLANK

f

H~

_..,.

TOE~

VE
SIDE

~

-...HEE L
...._

COAST
SIDE

If the pattern is not correct, remove and replace the
driven gear adjustment shim.
Replace the shim with a thinner one if the contact
pattern is too high.

TOO HIG H:

FAr~
DRIVE SIDE

13-14

c~

FACE

t

TRANSMISSION

Replace the driven gear adjustment shim with a
th icker one rf the contact is too low.

DRIVEN
GEAR/SHAFT

The pattern will shift about 1.5-2.0 mm (0.060.08 in) when the thickenss of the shim is changed
by 0. 10 mm (0.004 in).

OUTPUT DRIVEN GEAR ADJUSTMENT SHIM:
0.40 mm (0.016 in)
0.45 mm (0.018 in)
0.50 mm (0.020 in)
0.55 mm (0.022 in)
0.60 mm (0.024 in)

TOO LOW:

~

FLANK

COUNTERSHAFT

J----:.:: ~_tNK
SIDE

SIDE

BACKLASH INSPECTION
Place the output gear case in a vise wrth soft jaws or
a shop towel.
Set a horizontal type dial indicator on the counter·
shaft as shown.
Hold the driven gear with the shaft holder and
rotate the countershaft by hand until gear slack is
taken up.
Turn the countershaft back and forth to read
backlash.

SERVICE LIMIT: 0.40 mm (0.016 in)

Remove the dial indicator. Turn the countershaft
120° and measure backlash. Repeat this procedure
once more.
Compare the difference of the th ree measurements.

DIFFERENCE OF MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 in)

13-15

TRANSMISSION

If the difference in measurements exceeds the
limit, it indicates that the bearing is not installed
squarely. Inspect the bearings and reinstall if necessary.
If backlash is excessive, replace the countershah
gear adjustment shim with a thinner one.
If the backlash is too small, replace the counter·
shaft shim with a thicker one.
Backlash is changed by about 0.06-0.07 mm
(0.002-0.003 in) when thickness of the shim is
changed by 0.10 mm (0.004 in).
COUNTERSHAFT/OUTPUT DRIVE GEAR
ADJUSTMENT SHIMS:
0.40 mm (0.016 in)
0 .45 mm (0.018 in)
0.50 mm (0.020 in)
0.55 mm (0.022 in)
0 .60 mm (0.024 in)

13-16

TRANSMISSION

COUNTERSHAFT INSPECTION
NOTE:

Countershaft spacer selection should be performed whenever you replace any of the
following parts:
Crankcase (Section 1 1)
Countershaft bearing (Section 11)
• Countershaft
Select the correct output gear case gasket (page
13-15).
Install the output gear case assembly and new gasket
onto the lower case.
Assemble the transmission with the original spacer.
Measure the clearance between the bearing and
spacer with a feeler gauge.
CLEARANCE: 0.3-0.4 mm (0.012-0.016 in)
BEAR IN G

If the clearance exceeds the limit, select a spacer to
obtain the correct clearance:
SPACER/THICKNESS:
0.85 mm (0.033 in)
0.90 mm (0.035 in)
0.95 mm (0.037 in)
1.00 mm (0.039 in)
1.05 mm (0.041 in)

13-17

TRANSMISSION

SHIFT FORK AND SHIFT DRUM
REMOVAL
Bend the lock washer tab down and remove the
center fork mounting bolt.
Remove the shift fork shaft and shift forks.

Remove the bearing stopper plates.
Remove the shift drum.

GEAR SHIFT DRUM AND SHIFT
FORK INSPECTION
Inspect the shift drum end for scoring, scratches,
or evidence of insufficient lubrication.
Check the shift drum grooves for damage.

13-18

CENTER FORK

RIGHT FORK

FORK GUIDE
SHAFT

TRANSMISSION

Inspect the shift drum hole and shift fork shaft hole
for scoring or scratches.

Measure the sh,ift fork shaft O .D. at right and left
shift fork surfaces.
Check for scratches, scoring, or evidence of insuf·
ficient lubrication.
SERVICE LIMIT: 13.90 mm (0.547 in)

Measure the right and left shift fork I .D.
Measure the shift fork claw thickness.
SERVICE LIMITS:
I. D. (right and left fork) :
'83-'85:
After '85:
CLAW THICKNESS :

14.05 mm (0.553 in)
14.07 mm (0.554 in)
6.1 mm (0.24 in)

13-19

TRANSMISSION
SHIFT DRUM

INSTALLATION
Install the shift drum .
Apply a locking agent to the screw threads and
install the bearing stopper plates.

SHIFT FORK SHAFT
Install the shift forks and shaft.

CAUTION:
Install the shift fork shaft so that the plugged
end is toward the left side.
Install the lock washer and tighten the center fork
bolt.
TORQUE: 16-20 N·m (1.6-2.0 kg-m, 12-14 ft-lb)

Bend the lock washer tabs up.

13-20

SHIFT FORKS

TRANSMISSION
DRIVER
07742-0030100

TRANSMISSION ASSEMBLY
MAINSHAFT
Install the mainshaft bearing with the special tools
as shown.

ATTACHMEN , 30 mm I.D.
077 46- 0030300
Check the gears for freedom of movement or rota·
tion on the shaft.
Check that the snap rings are seated in the grooves.

MAINSHAFT

/

~. ~
~

M5

I

~

@~
M4

13-21

TRANSMISSION

COUNTERSHAFT
ft in the crankcase,
.
Beforethe
placmg
dthe
C6countersha
gears, washers, and collar.
install
C4 an

alg~m

nd splined cola~
.. g the tab of
the splined
IInstall the C3 gear/washer while
"th groove In
tall the stoppe
WI
ns
washer
the stopper
l
co iar. bl e the C2, C5, and Cl gears, wa shers, and
Assem
collars.

13-22

..

C4

SPUN ED COLLER

TRANSMISSION

Install the lower crankcase (Refer to Section 11).
NOTE :
Check the oil orifice for clogging, before
installing the lower crankcase.

- -- -- - --'

OIL ORIFI CE

13-23

DRIVE TRAIN

8 mm : 23-282 N8 .kmg-m 17- 20 ft-lb)
(2.3- .
•
10 mm: 35- 454 N5 ·kmg m 25-33 ft-lb)
(3.5- .
- •

;

-

~

100-120 N-m
(10- 12 kg-m,

72-87 ft·lb)

\

~
~

14-0

~

li}

~ ~.
~

rJ
~

("\~-._

rf'\.~
~\!,

.~
100-120N-m

()\J

"-.(10- 12kg-m,
72-87 ft-lb)

~

,y

@

~
I&~(:}

0~

45-70N·m
(4:5-7.0 kg·m, 33-51 ft·lb)

14. DRIVE TRAIN
SERVICE INFORMATION

14- 1

TROUBLESHOOTING

14- 2

FINAL DRIVE REMOVAL

14-3

DRIVE SHAFT

14- 3

FINAL DRIVE GEAR

14- 6

FINAL DRIVE INSTALLATION

14- 18

SERVICE INFORMATION
GENERAL
•
•
•

The final drive gear assembly must be removed together w ith the drive shah.
Replace all oil seals and 0 -rings whenever the final drive gear assembly is disassembled .
Check tooth contact pattern and gear backlash when the bearing, gear set and/or gear case have been replaced.

SPECIF ICATIONS
'83:
SERVICE LIMIT

STANDARD
Final gear oil

Capacity
Recommended oil

Gear backlash

170 cc (5.7 ozs) after disassembly

-

Hypoid-gear o il API, GL- 5
Above 5° C/41 ° F SAE #90
Below 5° C/ 41 ° F SAE #80

0.30 mm (0.012 in)

0.08- 0.18 mm (0.003-0.007 in)

Gear assembly preldad
Damper case oil capacity
Damper cam spring free length

-

0.2-0.3 N-m (2-3 kg-em, 1.7 - 2.6 in-lb)
80 cc (2.7 oz)
65 mm (2.6 in)

63 mm (2.5 in)

STANDARD

SERV ICE LI M IT

After 83:
Final gear oil

Capacity
Recommended oil

Gear backlash
Gear assembly preload

150 cc (5.1 oz) after disassembly

-

-

Hypoid gear oil: SAE #80
0.08- 0.18 mm (0.003- 0.007 in)
0.2-0.3N·m (2- 3 kg-m, 1.7- 2.6 ft-lb)

Damper case oil capacity

80 cc (2. 7 oz)

Damper cam spring free length

65 mm (2.6 in)

-

0.30 mm (0.012 in)
-

63 mm (2.5 in)

TORQUE VALUES
Pinion bearing retainer
Pinion nut
Gear case cover bolt 10 mm
8mm
Final gear case attaching nut
Rear axle nut
Axle pinch bolt

100- 120 N-m (10- 12 kg-m, 72-87 ft-lb)
100-120 N-m (10- 12 kg -m, 72- 87 ft-lb)
35-45 N-m (3.5- 4.5 kg-m, 25- 33 h -lb)
23- 28 N-m (2.3-2.8 kg-m, 17-20 ft -lb)
45-70 N-m (4.5-7.0 kg-m, 33- 51 ft -lb)
85-105 N·m (8.5-10.5 kg-m, 61 76 ft -lb)
20-30 N·m (2.0- 3.0 kg-m, 14-22 ft·lb)

14-1

DR IVE TRA IN
TOOLS
Special
Drive shaft dis/assembly tool
Drive shaft dis/assembly tool C
Retainer wrench
Final pinion holder
Shaft puller

Bearing race insert attachment
Bearing puller & driver attachment
Ball race & bearing driver attachment

07964-MB40 100
07964-MB00300
07910-4630100
07926-ME90000
07931 - ME40000 or Pinion puller set 07935-MBOOOOO
or Pinion puller 07931-4630200 and
Pinion puller attachment kit
07931 - M 800000
07931-4630300
07934-MBOOOOO
07945-3330300

Common
Driver
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm
Pilot, 30 mm
Driver C
Attachment, 25 mm I.D.
Shock absorber compressor

TROUBLESHOOTING
Excessive noise
1. Worn or scored ring gear shaft and driven flange
2. Scored driven flange and wheel hub
3. Worn or scored drive pinion and splines
4. Worn pinion and ring gears
5. Excessive backlash between pin ion and ring gear
6. Oil level too low
Oil leak
1. Clogged breather
2. Oil level too high
3. Seals damaged

14-2

077 49-001 0000
07746- 0010300
077 46-001 0400
07746-0010100
077 46-001 0200
077 46- 0040700
07742-0030100]
.
_
or Dnver 07945-3710200
07746 0030200
07959-3290001

DRIVE TRAIN

FINAL DRIVE REMOVAL

FINAL DRIVE CASE
ATTACHING NUTS

Place the motorcycle on its center stand. Drain the
final gear oil (page 2-1 0) and remove the rear wheel
(page 16-3).
Remove the leh shock absorber (page 16-9).
Place an oil drain pan under the gear case and swing
arm mating surfaces to catch any damper cam oil
that may leak out during removal of the gear case.
Remove the final gear case attaching nuts and
remove the gear case from the swing arm.

DRIVE SHAFT
REMOVAL
If the drivershaft came out of the swing arm attach·
ed to the final gear case, do the following:
Insert the axle through the gear case and secure the
case in a vise with soft jaws or shop rags by clamping the axle. Place the shock mount between the
jaws for stability.
Place an oil drain pan under the damper case to
catch the damper oil that will spill out.
Separate the damper unit from the gear case by
gently revolving the damper in a circular motion
while tugging slightly.
After removing the damper unit from the gear case,
remove and discard the outer stop ring that lies in
the groove on the splined end of the damper. This
ring serves as an aid in mass production, and should
not be installed when the final drive is reassembled.

/

~ -. £ ~

1D

OUTER STOP RING:
Discard it.

DIS/ASSEMBLY TOOL (PLATE)
07964-MB40100

DISASSEMBLY
Drain the gear oil from the damper case.
Remove the large spring clip from the damper cam
to avoid damaging it.
Compress the drive shah with the rear shock absorber compressor and attachment tools.
REAR SHOCK
ABSORBER
COMPRESSOR
07959-3290001

DIS/ASSEMBLY TOOL C (EXTENSION)
07964-MB00300

14-3

DRIVE TRAIN

Remove the spring stop ring and drive shaft from
the compressor.

SPRING STOP RING

RCAM
Remove the spring stop, damper cam, and damper
lifter from the drive shaft.
Check the damper lifter and cam for wear or
damage.

CAUTION:
Discard the stop ring and install a new one
upon reassembly.

?\

SPRING STOP

STOP RING

DAMPER CASE
Remove the oil seal and oil seal guide from the
damper case.
NOTE:

Replace the oil seal with a new one if it is
removed.

14-4

DRIVE TRAIN
DAMPER CAM SPRING
Remove the damper cam spring.
Measure the damper cam spring free length.
SERV ICE LIMIT: 63 mm (2.5 in)

FREE LENGTH
DAMPER CASE
Remove the damper case and 0 -ring from the drive
shaft.
Inspect the 0-ring and replace it if necessary.
Replace the damper case on the drive shaft.

0 -RING

DRIVE SHAFT

ASSEMBLY

DRIVER

07749- 0010000
Install the damper cam spring into the damper case.
Drive the oil seal guide and oil seal in with the driver
and attachment.
Assemble the remaining parts in the reverse order
of disassembly.
NOTE:
Replace the 0-ring, oil seal, and stop ring with
new ones when reassembling the dr ive shaft.

ATTACHMENT, 52 x 55 mm

07746- 0010400

14-5

DRIVE TRAIN

FINAL DRIVE GEAR
RING GEAR REMOVAL
Remove the distance collar.
Remove the dust guard plate bolts. Remove the dust
guard plate by turning it clockwise.

DUST GUARD PLATE
CASE COVER

Remove the eight case cover bolts and cover. If the
ring gear stays in the cover, do the following :
Place the cover in a press with the ring gear down.
Make su re the cover is well supported.
Press the ring gear out of the cover with driver
07749-0010000 and attachment 07746-0010100.

\
RING GEAR

Remove the ring gear from the final drive case.
Remove the O·ring guide by tapping it from the
opposite side.

14-6

O·RING GUIDE

DRIVE TRAIN
RING GEAR BEARING REMOVAL

ATTACHMENT, 32 x 35 mm 07746-0010100
PILOT, 30 mm 07746-0040700
BEARING PULLER
(COMMERCIALLY
AVAI LABLE)

Remove the ring gear bearing and gear adjusting
spacer.

/

RING GEAR BEAR ING

CASE COVER 01 L SEAL REPLACEMENT

OIL SEAL

Remove the oil seal from the case cover and press
in a new oil seal.

PINION GEAR REMOVAL
Install the pinion joint holder onto the pinion joint
and remove the pinion shaft nut.
Remove the tool and p1nion jo1nt.

PIN ION HOLDER
07926-M E90000

14-7

DRIVE TRAIN

Remove the retainer lock tab.

BOLT

LOCK TAB

Remove the pinion retainer with the lock nut
wrench .

.· .

.it

·~

·_·:·· ~

~3: : ~;' · :

PINION HOLDER 07926-MEOOOOO PINION PULLER ATTACHMENT KIT
WITH SHAFT PULLER
OR 07931 - MBOOOOO WITH PINION
07931-ME40000
PULLAR 07931-4630200
Pull off the pinion assembly with the pinion puller.
OR PINION PULLER SET
07935- MBOOOOO

14-8

DR IVE TRAIN
0-RING

PINION BEARING REMOVAL
Remove the 0-ring from the pinion shaft.

PINION BEARING

BEARING PULLER
(COMMERCIALLY AVAILABLE)

Pull the outer and inner bearing races off the shaft
with the bearing puller.
Pull the remaining inner race off with the same tool.
Remove the pinion adjustment spacer.

DRIVER

PINION RETAINER OIL SEAL
REPLACEMENT

OIL SEAL

07749-0010000

Remove the 0 -ring and oil seal from the pinion
retainer.
Drive a new oil seal into the retainer.
Coat a new 0 -ring with oil and install it onto the
retainer.
To install new oil seal, use driver 07945-3330300.

14-9

DR IVE TRAIN
CASE BEARING AND OIL SEAL
REPLACEMENT

RING GEAR BEARING

PINION BEARING

Heat the gear case 80° C ( 176° F). Tap the gear case
with a plastic hammer and remove the ring gear and
pinion bearings.

Always wear gloves when handling the gear
case after it has been heated.
NOTE:
Use bearing remover, 35 mm, 07936-3710400
to remove ring gear case bearing.

Remove the ring gear shaft oil seal.

DRIVER
07749-0010000

..

OIL SEAL

Drive a new oil seal into the case, using the special
tools shown.

Drive new pinion and ring gear bearings into the
case.

DRIVER
07749-0010000

ATTACHMENT
07945-3330300

ATTACHMENT, 52 x 55 mm
07746-0010400

14-10

DRIV E T RA IN
BREATHER HOLE CLEANING

CASE COVER

BREATHER CAP

Remove the breather hole cap and blow through the
breather hole with compressed air.

PINION GEAR ASSEMBLY

PINION BEARING

Install the original pinion gear spacer.
NOTE :

When the gear set, pinion bearing and/or gear
case have been replaced, use a 2.0 mm thick
spacer.

DRIVER

DRIVER

07742- 0030100 OR 07945-3710200
Press the bearing onto the pinion gear shaft with the
special tools shown.

r ,

Install a new 0-ring over the pinion shaft.

ATTACHMENT, 25 mm I.D.

0-R ING

07746- 0030200

14-11

DRIVE TRAIN
RETAINER WRENCH

07910-4630100
•· ..w•.

Place the pinion assembly into the gear housing.
Drive the pinion assembly into the gear case until
pinion retainer threads can engage with the case
threads.
Apply gear oil to the 0 -ring and threads on the
pinion retainer. Install the 0-ring guide tool.
Screw in the pinion retainer to press the pm10n
bearing in place, then tighten it to the specified
torque.
TORQUE:

100-120 N-m (10-12 kg-m, 72-87 ft-lb)

RING GEAR ASSEMBLY
Install the original spacer onto the ring gear.
NOTE:

If the gear set, pinion bearing, ring gear bearing and/or gear case are replaced, install a 2.0
mm thick spacer.

Place a new ring gear bearing on the ring gear shaft.
Place the old bearing on top of it. Then, drive the
new bearing onto the shaft with the old bearing and
attachment. Then remove the old bearing.

14-12

RING GEAR SPACER

DRIVE TRAIN
0-AING GU IDE
Install a new 0 -ring on the 0-ring guide .
Apply grease to the 0-ring and drive the 0 -ring
guide onto the ring gear shaft.

0 -RING •

DRIVER
07749- 0010000

~

ATTACHMENT, 42 x 47 mm
077 46-0010300
Install the ring gear into the gear case cover.
Measure the clearance between the ring gear and
the ring gear stop pin with a feeler gauge.
CLEARANCE : 0.30-0.60 mm (0.012- 0.024 in)

STOP PIN

If the clearance exceeds the service limit, remove
the ring gear. Heat the gear case cover to approxmaterly 80° C (176°F) and remove the stop pin by
tapping the cover.

STOP PIN

Always wear gloves when handling the gear
case after it has been heated.
Install a stop pin shim to obtain the correct clearance.
SHIM THICKNESS:

A 0.10 mm (0.004 in)
B 0.15 mm (0.006 in)

Instal l the shim and drive the stop pin into the case
cover.

STOP PIN

SHIM

14-13

DRIVE TRAIN
Clean all sealing material off the mating surface of
the gear case and cover.
NOTE:

Q

ep dust and dirt out of the gear case.
careful not to damage the mating
rfaces.

- - - --'

Apply liquid sealant to the mating surface of the
gear case cover.

GEARTOOTHCONTACTPATTERN
CHECK

PRUSSIAN BLUE

WAVE WASHER

Apply a thin coat of Prussian Blue to the pinion
gear teeth for a gear tooth contact pattern check.
Place the wave washer and ring gear into the gear
case.
Apply gear oil to the lip of the 011 seal on the gear
case cover and install the gear case cover.

8 mm BOLTS
Tighten the cover bolts in 2-3 steps until the cover
evenly touchs the gear case, then tighten the 8 mm
bolts to the specified torque in a crisscross pattern
in two or more steps.
TORQUE : 23-28 N-m (2.3-2.8 kg·m, 17-20 ft·lb)

Then tighten the 10 mm bolts.
TORQUE : 40- 50 N·m (4.5-5.0 kg·m, 33-36 ft-lb)

14-14

10 mm BOLTS

DRIVE TRA IN

Remove the oil filler cap from the final gear case.
NORMA L
Rotate the ring gear several times in the normal
direction of rotation. Check the gear tooth contact
pattern through the oil filler hole. The pattern is
indicated by the Prussian Blue applied to the
pinion before assembly.

I
I

Contact is normal if the Prussian Blue is transfered
to the approximate center of each tooth and slightly
to the flank side.

HE~

FACE
FLANK

I .,

-

TOE

, ~
COAST SIDE

FLANK

TOO HI GH

I

F7&
DRIVE SIDE

Replace the pinion spacer with a thinner one if the
contacts are too low, to the flank side. The patterns
will shift about 1.5-2.0 mm (0.06-0.08 in) when
the thickness of the spacer is changed by 0.10 mm
(0.004 in).

-HEEL

~FACE

DR IVE SIDE

If the patterns are not correct, remove and replace
the pinion spacer. Replace the pinion spacer with a
thicker one if the contacts are too high, toward the
face.

-.

PIN ION SPACE R

~FACE

·~

t

COAST SIDE

TOO LOW

I

PINI ON SPACER :

A
B
C
D
E
F
G

1.82 mm
1.88 mm
1.94 mm
2.00 mm
2.06 mm
2.12 mm
2.1 8 mm

(0.072 in)
(0.074 in)
(0.076 in)
(0.079 in) Standard
(0.081 in)
(0.084 in)
(0.086 in)

FLANK~

~
DR IVE SIDE

~

~

FLAN K

COAST SIDE

14-15

DRIVE TRAIN
BACKLASH INSPECTION
Remove the oil filler cap.
Set the final gear assembly into a jig or stand to
hold 1t steady. Set a horizontal type dial indicator
on the ring gear. through the oil filler hole.
Hold the pinion gear spline by hand. Rota te t he ring
gear by hand until gear slack is taken up. Turn the
ring gear back and fo rth to read backlash.
SERVICE LIMIT: 0.30 mm (0.02 in)

Remove the dial indicator. Turn the ring gear 120°
and measure backlash. Repeat this procedure once
more.
Compare the difference of- the t hree measurements.
DIFFERENCE OF MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 in)

If the difference in measurements exceeds the limit,
it indicates that the bearing is not installed squarely.
Inspect the bearings and reinstall if necessary.
If backlash is too small. replace the ring gear spacer
with a thinner one.
Backlash is changed by about 0.06-0.07 m m
(0.002-0.003 in) when t hickness of the spacer is
changed by 0.10 mm (0.004 in).
RING GEAR SPACER :
A 1.82 mm (0.072 in)
B 1.88 mm (0.074 in)
C 1.94 mm (0.076 in)
D 2.00 mm (0.079 in) Standard
E 2.06 mm (0.081 in)
F 2.12 mm (0.084 in)
G 2.18 mm (0.086 in)
H 2.24 mm (0.088 in)
I 2.30 mm (0.091 in)

14-16

RING GEAR S P A~ER

DRIVE TRAIN
PINION JOINT INSTALLATION
Install the appropriate pinion retainer lock tab.
NOTE:
There are two types of lock tabs as shown.

LOCK TABS

Apply gear oil to the oil seal lip contact surface
of the pinion joint and install the pinion joint.

PINION HOLDER

07926- ME90000
Install the pinion joint holder tool and tighten the
pinion nut.
TORQUE: 100-120 N·m (10-12 kg·m,

72-87 ft-lb)
Remove the pinion joint holder tool.

Make sure that the gear assembly rotates smoothly
without binding by turning the pinion joint.

14-17

DRIVE TRA IN
DISTANCE COLLAR
Install the dust guard plate and torque the bolt.
Install the distance collar.

DUST GUIDE PLATE

FINAL DRIVE INSTALLATION
Fill the damper case with the recommended type
and amount of lubricant.
'83:
RECOMMENDED OIL: HYPOI D GEAR OI L API,
GL-5
Above 5°C/41 ° F: SAE #90
Below 5° C/41 ° F: SAE #80
OIL CAPACITY: 80 cc (2.7 oz)
After '83:
RECOMMENDED OIL: HYPOID GEAR OIL
SEA #80
OI L CAPACITY: 80 cc (2.7 oz)

Keeping the damper case vertical, place the damper
spring onto the damper cam and install the final
drive gear case over the damper cam.
NOTE :
Be careful not to damage the damper case
oil seal during assembly.
• Do not let the gear case separate from the
damper case or the oil will spill out.

14-18

FINAL GEAR CASE

DAMPER SPRING

DRIVE TRAIN

Make sure the universal joint is in line with the
driveshaft. Then insert the drivershaft into the
swing arm aligning its splines with the outer shaft
splines. Keep the gear case and damper case together
or damper oil will leak out.
Secure the gear case to the swing arm with the three
attaching nuts. To ease axle installation, do not
tighten the gear case nuts until after the axle is
installed.
Install the rear wheel (page 16·8).
Tighten the axle nut.
TORQUE:
85-105 N-m (8.5-10.5 kg·m, 61-76 ft-lb)
Tighten the three final gear case attaching nuts.
TORQUE: 45-70 N·m (4.5-7.0 kg·m, 33-51 ft-lb)
Tighten the axle pinch bolt.
TORQUE: 20-30 N·m (2.0-3.0 kg-m, 14-22 ft-lb)
Install the shock absorber (page 16-13).
Make sure that the drain bolt is tightened.
Remove the oil filler cap and pour in the specified
amount of recommended oil.
'83:
RECOMMENDED OIL: Hypoid Gear Oil API, GL-5
Above5°C {41°F): SAE # 90
Below 5°C (41° F): SAE #80
OIL CAPACITY:·
170 cc {5.7 oz) Dry
130 cc (4.4 oz) Refill after draining
After '83:
RECOMMENDED OIL: Hypoid Gear oil
SAE #80
OIL CAPACITY:
150 cc {5.1 oz) Dry
130 cc (4.4 oz) Retill after draining

14-19

FRONT
- - WHEEL/ SUSPENSION

5-30 N-m
2-5-3.0 k g-m, 18-22
9-13 N·m
ft·lb)
.A

30-45 N·m
(3.0-4 .5 k g·m
22-33 ft·lb) •
18-30 N·m
(1.8-3.0 k g-m
13-22 ft·lb) •

15-0

(0.9-1 .3 kg-m, 7-9 ft-lb)

15. FRONT WHEEL/SUSPENSION
SERVICE INFORMATION

15-1
15-2
15-3
15-4
15-6

TROUBLESHOOTING
FUSE/COUPLER BOX
HEADLIGHT
INSTRUMENTS

15-9
15-11
15- 18
15-25
15- 38

IGNITION SWITCH
HANDLEBARS
FRONT WHEEL
FRONT FORKS
STEERING STEM

SERVICE INFORMATION
GENERAL
•

A jack or other support is required to support the motorcycle.

SPECIFICATIONS

-

STANDARD

SERVICE LIMIT

-

0.2 mm (0.01 in)

Radial

0.3 mm (0.01 in) max.

2.0 mm (0.08 in)

Axial

0.3 mm (0.01 in) max.

2.0 mm (0.08 in)

-

0.03 mm (0.001 in)

Axle shaft runout
Front wheel rim runout

f---

Wheel bearing play
~

414.7 mm (16.33 in)

Fork spring free length
Fork tube runout

-

Front fork fluid capacity

Right 565 cc (19.1 oz). Left 580 cc (19.6 oz)

0-40 kPa (0-0.4 kg/cm

Front fork air pressure

2

,

0-6 psi)

--

404 mm ( 15.9 in)
0.2 mm (0.01 in)

-

TORQUE VALUES
Handlebar upper holder
Handlebar pinch bolt
Caliper mounting bolt
Front axle nut ·
Front axle pinch bolt
Front fork socket bolt
Fork tube cap
Steering bearing adjustment nut
Steering stem nut
Brake d isc

'83:
After '83:
'83, '84, '85:
After '85:
'83, '84, '85:
After '85:

Front fork top pinch bolt
Front fork bottom pinch bolt
Front fork stabilizer bolts
Front brake master cylinder holder bolt
Clutch master cylinder holder bolt

40-50 N ·m (4.0-5.0 kg·m, 29- 36 ft·lb)
25- 30 N-m (2.5- 3.0 kg-m, 18-22 ft·lb)
30- 45 N·m (3.0- 4.5 kg·m, 22-33 ft-lb)
55-65 N·m (5.5- 6.5 kg·m, 40- 47 ft·lb)
18- 30 N-m (1.8- 3.0 kg-m, 13-22 ft·lb)
15-25 N·m (1 .5-2.5 kg·m, 11 - 18 ft·lb)
15-30 N·m (1.5-3.0 kg·m, 11-22 ft·lb)
14-16 N·m (1.4-1.6 kg·m, 10-12 ft·lb) {See pages 15-41 and 42)
19-23 N·m (1.9-2.3 k9·m, 14- 17 ft·lb)
80- 120 N ·m (8.0-12.0 kg-m, 58-87 ft-lb)
90-120 N·m (9.0-12.0 kg·m, 65-87 ft·lb)
25- 30 N ·m (2.5-3.0 kg-m, 18-22 ft·lb)
37-43 N ·m (3.7- 4.3 kg·m, 27-31 ft·lb)
9-13 N·m (0.9- 1.3 kg-m, 7-9 ft:tb)
45- 55 N·m (4.5- 5.5 kg·m, 33-40 ft·lb)
18-28 N·m (1.8- 2.8 kg·m, 13-20 ft·lb)
10-14 N·m (1.0-1.4 kg·m, 7- 10 ft·lb)
10-14 N·m (1.0-1.4 kg·m, 7- 10 ft·lb)

15-1

FRONT WHEEL/SUSPENSION
TOOLS
Special
Hex . wrench, 6 mm
Snap ring pliers
Fork seal driver
Fork seal driver attachment
Steering stem socket
Ball race driver
Ball race remover
Race remover attchment
Steering stem driver
Driver

07917-3230000 or commercially available
07914-3230001 or commercially available
07947-KA50100
07947- KF00100
07916-3710100
07946-3710701
07946-371 0500
07953-MJ1000A (U.S.A. only)
07946-MBOOOOO or 07946-3710601 and 07964- MB00200
07949-3710001 or 07949-3710000

Common
Driver
Attachment, 42 x 47 mm
Pilot, 15 mm
Lock nut wrench, 30 x 32 mm
Extension bar
Bearing remover shaft
Bearing remover head, 15 mm
Attachment, 37 x 40 mm

07749-0010000 or Driver 07949-6110000
077 46-0010300
077 46- 0040300
07716-0020400 or commercially available
07716- 0020500 or commercially available
07746-0050100
077 46-0050400
077 46-001 0200

TROUBLESHOOTING
Hard steering
1. Steering bearing adjustment nut too tight
2. Faulty steering stem bearings
3. Damaged steering stem bearings
4. Insufficient tire pressure
Steers to one side or does not track straight
1. Unevenly adjusted right and left shock absorbers
2. Bent front forks
3. Bent front axle
4. Wheel installed incorrectly
Front wheel wobbling
1. Bent rim
2. Worn front wheel bearings
3. Faulty tire
4. Axle nut tightened improperly
Soft suspension
1. Weak fork springs
2. Insufficient fluid in front forks
3. Front fork air pressure incorrect
Hard suspension
1. Incorrect fluid weight in front forks
2. Front fork air pressure incorrect
3. Bent fork tubes
4. Clogged fluid passage
5. Clogged anti-dive orifice
Front suspension noise
1. Worn slider or guide bushings
2. Insufficient fluid in forks
3. Loose front fork fasteners
4. Lack of grease in speedometer gearbox

15-2

FRONT WHEEL/SUSPENSION

FUSE/COUPLER BOX
REMOVAL/INSTALLATION
Remove the fuse holder cover.

Disconnect the horn wires from the horn terminals.

COU PLER BOX COVER

Remove the bolt attaching the horn bracket.
The bracket and horns will come off as an assembly.
Remove the coupler box cover.

Disconnect all wire couplers and connectors in the
coupler box. Note their position for ease of reinstallation.

15-3

FRONT WHEEL/SUSPENSION

Remove the two coupler box attaching bolts and
the coupler box.

'83, '84, '85:

HEADLIGHT
REMOVAL/INSTALLATION
Remove the headlight mounting screw. ('83, '84,
'85)
Pull out the headlight from the headlight case.
After '85:
Remove the headlight mounting bolt.

HEADLIGHT MOUNTING
HEADLIGHT
Disconnect the wire coupler and remove the headlight.
Installation is the reverse order of removal.

15-4

BOLT
WIRE COUPLER

FRONT WHEEL/SUSPENSION

CASE REMOVAL/INSTAL LATI ON
Remove the headlight case mounting bolts and the
headlight case.
Install the headlight case in the reverse order of
removal.

HEADLIGHT BRACKET

BRACKET REMOVAL/INSTA LLAT ION
Remove the coupler box cover (page 15·3) .
Disconnect the front tum signal wire connectors.
Remove the headlight bracket mounting bolts and
bracket/turn signal assemblies.
Install the headlight bracket in the reverse order
of removal.

BOLT

15-5

FRONT WHEEL/SUSPENSION

INSTRUMENTS
IND ICATOR LI GH T BULB
REPLACEMENT
Remove the headlight and case (pages 15-4 and
15-5).
Remove the instrument lower cover attaching
screws, and lower cover.

SCREWS

Remove the indicator panel attaching screws and
panel.

Replace any inoperative bu lbs.
After installing a new bulb, check for continuity.
If the new bulb does not light, inspect the wiring for
an open or short circuit, or loose connections.

15-6

INDICATOR PANEL

FRONT WHEEL/SUSPENSION

INSTRUMENT REMOVAL
Remove the coupler box cover (page 15·3) .
Remove the headlight and case (pages 15-4 and
15·5).
Disconnect the speedometer cable from the instru·
ments.
Disconnect the instrument wire couplers.
Remove the instrument mounting nuts and instrument.

SPEEDOMETER CABLE

DISASSEMBL Y

SCREWS

Remove the instrument lower cover.

CAUTION:
Do not leave the instruments upside down or
damping fluid will leak onto the inside of the
lens.

LOWER COVER

Remove the meter setting nuts and meters.

15-7

FRONT WHEE L/SUSPENSION
LOWER COVERS

Remove the meter lower cover screws and lower
covers.

Replace any inoperative bulbs.
If a replacement bulb does not light, check the
wiring for a short or open circuit, or check for
loose connections.

ASSEMBLY/INSTAL LAT ION
Lubricate the speedometer cable before reconnecting it.
Assemble and install the instruments in the reverse
order of disassembly and removal.

15-8

FRONT WHEEL/SUSPENSION

IGNITION SWITCH
REMOVAL/INSTALLATION
Remove the headlight and headlight case.
Remove the coupler box cover (page 15-3) .
Remove the instruments (page 15·7) .
Disconnect the ignition switch wire coupler.
Remove the ignition switch mounting bolts, and
ignition switch.
Install the ignition switch in the reverse order of
removal.

BO LTS

DISASSEMBLY/ASSEMBLY
'83, '84, '85:
Open the wire clamp.
Insert the ignition key and turn it to between the
ON and OFF detent positions.

WIRE CLAMP
SLOTS

Push the lugs into the slots and pull the contact
base from the switch.
Assemble the ignition switch in the reverse order of
disassembly.

LUGS

15-9

FRONT WHEEL/SUSPENSION
AFTER '85:
Insert the ignition key and turn it between the ON
and OFF detent positions.

Cut the wire clamp.
NOT E:
Replace the wire clamp with new one whenever it is removed.
Remove the three screws.

WIRE CLAMP

Push the lugs into the slots and pull the contact
base from the switch.
Assemble the ignition switch in the reverse order of
disassembly.

LUGS

15-10

FRONT WHEEL/SUSPENSION

HANDLEBARS
'83, '84, '85:
REMOVAL/INSTALLATION
Disconnect the clutch switch wires.
Remove the clutch master cylinder.

Disconnect the choke cable from the choke lever.

EBAR SWITCH
Remove the left handlebar switch.

15-11

FRONT WHEEL/SUSPENSION

Remove the right handlebar switch and disconnect
the front brake switch wires.

Remove the brake master cylinder.

MASTER CYLINDER

HANDLEBAR PINCH BOLT

Remove the handlebar set screw.
Loosen the handlebar pinch bolt and remove the
handlebar.

J

HANDLEBAR SETSCREW

15-12

FRONT WHEEL/SUSPENSION

Remove the bolt caps and the handlebar cover.
Remove the handlebar upper holder bolts.
Remove the handlebar upper holders and the center
handlebar.

HANDLEBAR COVER

CENTER HANDLEBAR

INSTALLATION
Place the center handlebar onto the lower holder,
aligning its punch mark with the upper surface of
the lower holder.
Place the upper holder onto the lower holder with
its punch mark facing forward.
Tighten the forward bolts first, then tighten the
rear bolts.
TORQUE: 40-50 N·m (4.0-5.0 kg-m, 29-36 ft-lb)
Install the bolt caps and handlebar cover.

PUNCH MARK

HANDLEBAR COVER
PINCH BOLT
Install the right and left handlebars into the center
handlebar.
Install the handlebar set screws.
Apply grease to the handlebar pinch bolts.
Tighten the pirich bolts after aligning the punch
marks with the slits on the center handlebar.
TORQUE: 25-30 N-m (2.5-3.0 kg-m, 18-22 ft-lb)

SET SCREW

15-13

FRONT WHEE L/SUSPENSION

Apply grease to the throttle grip sliding surface and
install the throttle grip over the handlebar.

PUNCH MARK
Install the front brake master cylinder with "UP"
mark facing up.
Align the end of the holder with the handlebar
punch mark.
Tighten the upper bolt first, then the lower bolt.
TORQUE : 10- 14 N·m (1 .0 - 1.4 kg-m, 7- 10 f t-lb)
Connect the brake light switch wires.

BRAKE LI GHT SWITCH WIRES

Install the right and left switches by aligning the
locating pin with the hole in the handlebar.
Tighten the forward screw(s) first, then tighten the
rear screw.

PIN

15-14

"UP" MARK

FRONT WHEEL/SUSPENSION

Connect the choke cable to the choke lever.

CHOKE LEVER

CHOKE CABLE

Install the clutch master cylinder.
Align the end of the holder with the punch mark
on the handlebar.
T ighten the upper bolt first, then tighten the lower
bolt.
TORQUE : 10- 14 N·m (1.0-1.4 kg·m, 7- 10ft-lb)
Connect the clutch screw wires.

AFTER '85:
REMOVA L/INSTALLATION
Disconnect the clutch switch wires.
Remove the clutch master cylinder ('83-'85 as
shown).
Remove the two screws and open the left switch.

15-15

FRONT WHEEL/SUSPENSION

Disconnect the choke cable from the choke lever.

Remove the two screws and open the right handlebar switch.
Disconnect the throttle cable wires.
Disconnect the brake switch wires.
Remove the brake master cylinder.

BRAKE SWITCH WIRES

Remove the bolt caps.

15-16

THROTTLE CABLES

FRONT WHEE L/SUSPENSION

Remove the handlebar cover.
Remove the handlebar upper holder bolts, handle·
bar upper holder and handlebar.

HANDLEBAR UPPER HOLDER
H AND LEBAR UPPER HOLDER

INSTALLATION
Place the handlebar on the lower holder aligning the
punch mark with the upper face of the lower
holder.
Place the upper holders on the handlebar with the
punch marks facing forward.
Tighten the forward bolts first, then tighten the
rear bolts.

TORQUE: 40-50 N·m (4.0-5.0 k g-m, 29-36 ft-lb)

Install the bolt caps.

15-17

FRONT WHEEL/SUSPENSION

Connect the choke cable to the choke lever.
Install the right and left switches by aligning the
locating pin with the hole in the handlebar.
Tighten the forward screw(s) first, then tighten the
rear screw.

FRONT WHEEL
REMOVAL
Remove the speedometer cable set screw and the
speedometer cable.
Remove the right and left side caliper assemblies by
removing the bolts.
NOTE :
Do not operate the front brake lever after
removing the calipers. To do so will cause
difficulty in fitting the brake disc between
the brake pads.

Loosen the axle pinch bolt.
Loosen and remove the front axle.
Remove the front wheel.

15-18

AXLE PINCH BOLT

'

FRONT WHEEL/SUSPENSION
DISASSEMBLY
Remove the brake disc mounting bolts and discs.

SIDE COLLAR

Remove the side collar and right seal.

SEAL
Remove the left seal and speedometer gear retainer.

15-19

FRONT WHEEL/SUSPENSION
WHEEL INSPECTION
Check the rim runout by placing the wheel in a
truing stand. Turn the wheel slowly and read the
runout using a dial indicator.
SERVICE LIMITS:
RADIAL RUNOUT: 2.0 mm (0.08 in)
AXIAL RUNOUT: 2.0 mm (0.08 in)
NOTE :

The wheel cannot be repaired and must be
replaced with a new one if the service limits
are exceeded.

AXLE INSPECTION
Set the axle in V blocks and measure the runout.
SERVICE LIMIT: 0.2 mm (0.01 in)

WHEEL BEAR ING INSPECTION
Turn the inner race of each bearing with your
f inger. The bearings should turn smoothly and
quietly. Also check that the bearing outer race fits
tightly 1n the hub.
Remove and discard the bearings if the races do not
turn smoothly, queitly, or if they fit loosely in the
hub.
NOTE :

~

lace

hub bearings in pairs.

Pack new bearings with grease and install them into
the hub with the special tools.
For bearing replacement, see page 1 5-22.

15-20

FRONT WHEEL/SUSPENSION

Remove the wheel bearings and the distance collar
from the hub.
NOTE:

If the bearings are removed, they should be
replaced with new ones.

BEARING REMOVER
SHAFT 07746- 0050100

ASSEMBLY

'83, '84, '85:

AFTER '85:

\

I

NOTE:
The cast wheel does not use a rim band.
The front wheel uses a tubeless tire. For
tubeless tire repair, refer to the HONDA
TUBELESS TIRE MANUAL.

15-21

FRONT WHEEL/SUSPENSION
DR·IVER
077 49-0010000
Pack all bearing cavities with grease.
Drive in the right bearing first and press the distance
collar into place.
NOTE:
Be certain the distance collar is in position
before installing the left bearing.
Drive in the left bearing squarely.
NOTE:
Make sure that the bearings are fully seated
and that the sealed sides are facing out.

Install the speedometer gear retainer in the wheel
hub, aligning the tangs with the slots.

ATTACHMENT. 42 x 47 mm 07746-0010300
PILOT, 15 mm 07746-0040300
RETAINER

Install the left seal.

Install the right seal. Apply grease to the inner seal
lip and insert the side collar.

SEAL

15-22

FRONT WHEEL/SUSPENSION
'83, '84, '85:

AFTER '85:

Attach new gaskets to each brake disc.
GASK ETS

Install the brake disc with the "R" mark on the
right and the disc with the " L " mark on the left.
TORQUE :
' 83, '84, '85:
25- 30 N·m (2.5-3.0 kg·m, 18- 22 ft-lb)
After ' 85:
37- 43 N·m (3.7- 4.3 kg-m, 27- 31 ft-lb)
Install the speedometer gearbox in the wheel hub,
aligning the tangs with the slots.
Clean the brake discs with a high quality degreasing
agent.

INSTAL LATION
Fit the calipers over the discs, taking care not to
damage the brake pads. Install the caliper mounting
bolts.
TORQUE: 30-45 N·m (3.0-4.5 kg·m, 22- 33 ft·lb)
Align the speedometer gearbox with the tang on the
left fork leg as shown.
T ighten the axle to the specified torque.
TORQUE: 55-65 N·m (5.5- 6.5 kg·m, 40-47 ft·lb)

TA NG ON FORK LEG

15-23

FRONT WHEEL/SUSPENSION

Measure between the outside surface of the right
brake disc and the inside of the right caliper holder
with a 0. 7 mm (0.028 in) fee ler gauge.
If the gauge cannot be inserted, pull the right fork
out until the gauge can be inserted.

Tighten the axle pinch bolt to the specified torque.
TORQUE : 18- 30 N·m (1.8- 3.0 kg·m, 13-22 ft·lb)

There should still be at least 0.7 mm (0.028 in)
clearance between the caliper holder and disc.

CAUT ION:
After installing the wheel, apply the brakes
several times and recheck the clearance on
both sides. Failure to provide clearance will
damage the brake discs and affect braking
efficiency.

Install the speedometer cable.

15-24

.,.,....

FRONT WHEEL/SUSPENSION

FRONT FORKS
REMOVAL
Remove the following parts:
- front wheel.
- brake calipers.
- front fender.

Remove the fork brace.

FORK BRACE

Release fork air pressure.
Loosen the fork upper and lower pinch bolts.

15-25

FRONT WHEE L/SUSPENSION

Pull each fork tube down and out of the fork top
bridge and air joint. Rotate the fork tube while
pulling.
Remove the fork st op r ings.
Pull each fork tube out of the bottom bridge.

If service of the air joints is necessary, remove the
following parts:
- coupler box (page 15-3).
- headlight and case (pages 15-4 and 15-5).
- instruments (page 15-7).
Remove the two screws attaching the fork air joints
to the fork top bridge.

Remove the air joints.

15-26

FRONT WHEE L/SUSPENSION

Loosen the air joint pipe connectors and remove
the joint pipe.

JOINT PIPE

SEA L

/~

CONNECTOR

I~

0 -RING

DI SASSEMBLY

0

~

FORK TUBE CAP

Hold the fork t ube in a vise with soft jaws or a shop
towel and remove the fork, tube cap.

CAUTI ON:

I

Do not damage the sliding surface.

Remove the fork spring, spacer, and washer.
Force out the fork fluid by pumping the fork up
and down several times.

15-27

FRONT WHEEL/SUSPENSION

Hold the fork slider in a vise with soft jaws or a
shop towel.
Remove the socket bolt with a hex wrench .

HEX WRENCH (6 mm) 07917-3230000
OR COME.fH~!L
Y AVAILABLE IN U.S.A.

NOTE:
Temporarily install the spring and fork tube
cap if difficulty is encountered in removing
the bolt.
The piston and rebound spring can now be removed
from the right fork.

'83, '84, '85 :
SPONGE SEAL
'83, '84, '85:
Remove the dust seal, sponge seal, and plastic
washer. Discard the sponge seal and plastic washer.
After '85:
Remove the dust seal.
NOTE:
Do not reinstall the dust seal or sponge seal.
They are not needed.

DUST SEAL
SNAP RING PLIERS 07914-3230001
Remove the snap ring.

15-28

SNAP RING

OR COMMERCIALL! AVAILABLE IN U.S.A.

FRONT WHEEL/SUSPENSION

Pull the fork tube out until resistance from the
slider bushing is felt . Then move it in antf out.
tapping the bushing lightly until the fork tube
separates from the slider. The slider bushing will be
forced out by the fork tube bushing.
Remove the oil lock piece from inside the slider.

FORK TUBE
FORK SLIDER
BACK·UP
AFTER '85:
RING DUST SEALS

Remove the oil seal, back·up ring, and slider busing
from the fork tube.

NOTE:
Do not remove the fork tube bushing unless
it is necessary to replace it w ith a new one.

;/ )

FORK TUBE BUSHINGS

From the left fork, remove the circlip, oil lock
valve, spring, and spring seat from the piston.
Remove the piston and rebound spring from the
fork tube.

SLIDER
BUSHING

...' \''.,··

FORK TUBE
BUSHING

SPRING SEAT

PI

CIRCLIP

OIL LOCK
VALVE

SPR I NG

15-29

FRONT WHEEL/SUSPENSION
INSPECTION
FORK SPRING FREE LENGTH
Measure the fork spring free length.
SERVICE LIMIT: 404 mm (15.9 in)

ltU1W.Y~j

~

I.
FORK TUBE/ FORK SLIDER/ PISTON
Check the fork tube, fork slider, and piston for
score marks, scratches, or excessive or abnormal
wear. Replace any components which are worn or
damaged.
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.

PISTON RING
~
FORK TUBE

PISTV \

/'

REBOUND
SPR IN G

FORK TUBE
Set the fork tube in V blocks and read the runout.
SERVICE LIMIT: 0.2 mm (0.01 in)

15-30

SLIDER

~

FRONT WHEEL/SUSPENSION

BUSHING/BACK-UP RING
Visually inspect the slider and fork tube bushings.
Replace the bushings if there is excessive scoring or
scratching, or if the teflon is worn so that the
copper surface appears on more than 3/4 of the
entire surface.

BUSH ING

BACK-UP RING

Check the back-up ring; replace it if there is any
distortion at the points shown.
CHECK POl NTS
,_.

+-f.

-~

COPPER
SURFACES

ANTI -D IVE CASE

ANTI-DIVE CASE
Remove the four socket bolts and remove the antidive case.

Remove the piston and spring.
Remove the boots, pivot bolt collar, and stop
rubber.

SPRING

PIVOT BOLT CO LLA R

PISTON

·. oo
BOOT

-~

STOP RUBB ER

15-31

FRONT WHEEL/SUSPENSION

Check the spring and piston for wear or damage.

CHECK BALL
Remove the check valve setting screw, valve spring,
and check ball.

VALVE SPRING

Assemble the anti-dive case in the reverse order of
disassembly.

NOTE :
Apply a Thread Lock Agent to the threads
of the screws and socket bolts before
assembly.
Apply ATF to the piston and piston 0-ring.
Apply silicone grease to the pivot bolt
collar.
Install the pivot bolt collar boot holder
as shown.
BOOT HOLDER

15-32

FRONT WHEEL/SUSPENSION
CASE

Check the operation of the collar and piston.

d

STANDARD PISTON STROKE: 2.5 mm (0.10 in)

ASSEMBLY
Before assembly, wash all parts with a high flash
point or non-flammable solvent and wipe them off
completely.

('83-'85)
PLASTIC
FORK

'83-'85

WASHER

TUBE

SNAP

CAP~RING

~

~

SPACER

/ )FORK
""
TUBE

~

~

I

1~

I

/t
/
lJ

PISTON/
REBOUND
SPRING

OIL
LOCK
PIECE

~

I

Ofi:J~ !1:S._

SEAL

OIL SEAL

SLIDER

\

~\

/~

~CK·UPRING

~

""

~

~

O>·~oa,-=e
'SLIDER

11.

~SOCKET

FORK
TUBE
BUSHING

BOLT

CONNECTOR
AIR JOINT
.\

1

~

BUSHING

~

l/

SEAL

('83-'85)
SPONGE S:::.

('83-'85)
FORK
TUBE

~:z

~

~'

~-

AIR VALVE

~.

\

----FORK
STABILIZER
/ANTI-DIVE CASE

/

r~@):\
# ;
DRAIN BOLT

15-33

FRONT WHEEL/SUSPENSION

Insert the rebound spring and piston into the fork
tube.
On the left fork, install the spring seat, valve spring,
oil lock valve, and circlip on the piston.
Place the oil lock piece on the end of the piston
and insert the fork tube into the slider.

CIRCLIP

Place the fork slider in a vise with soft jaws or a
shop towel.
Apply a locking agent to the socket bolt and thread
it into the piston. Tighten with a 6 mm hex wrench.

OIL LOCK VALVE

HEX WRENCH, 6 mm 07917-3230000
OR COMMERCIA Y AVAILABLE IN U.S.A.

NOTE :
Temporarily install the fork spring and fork
tube cap to tighten the socket bolt.
TORQUE: 15-25 N·m (1.5-2.5 kg·m, 11-18 ft-lb)

Place the slider bushing over the fork tube and rest
it on the slider. Put the back-up ring and an old
bushing or equivalent tool on top.
Drive the bushing into place with the seal driver and
remove the old bushing or equivalent tool.
Coat a new oil seal with ATF and install it with
the seal markings facing up. Drive the seal in with
the seal driver.

FORK SEAL DRIVER
07947-KA50100

FORK SEAL DRIVER ATTACHMENT
07947-KF00100

15-34

VALVE SPRING

FRONT WHEEL/SUSPENSION
'83, '84, '85:
Install the snap ring with its radiused edge facing
down and install the plastic washer, the sponge seal,
and the dust seal.

After '85:
Install the snap ring with its radiused edge facing
down and install the dust seal.

SNAP RING PLIERS 07914- 3230001 OR
COM ME RCIALL Y A:.VIL=-BE;N~
=-,
'83,'84,'85:
AFTER '85:
DUST SEAL
SPONGE
SEAL
PLASTIC
WASHER
SNAP RING

\

NOTE :

OIL SEAL

Do not install a plastic washer or sponge seal.
They are not needed.

BACK-UP
RING
SLIDER
BUSHING

Pour the specified amount of ATF into the fork
tube.
CAPACITY:
Right fork : 565 cc (19.1 oz)
Left fork: 580 cc (19.6 oz)

AT F

Install the fork spring, spring seat, and spacer in the
fork tube.
NOTE:
Note the spring direction; the narrow pitches
should be at the top of the fork tube.

BOTTOM

TOP

15-35

FRONT WHEEL/SUSPENSION
FORK TUBE CAP
Install and torque the fork tube cap.
TORQUE: 15-30 N·m (1.5-3.0 kg·m, 11 -22 ft-lb)

INSTALLAT ION
If the air joints are d isassembled, install new 0-rings
in the air joint groove.
Install the air joint pipe connectors, with new seals
and O·rings over both ends of the air joint pipe and
loosely tighten the connectors.

Install the front forks and temporarily tighten the
lower fork pinch bolts.
Install the air joint stop rings in the grooves in the
fork tubes.
I nstall the fork air joints over the fork tubes and
tighten the connectors.
TORQUE : 4- 7 N·m (0.4-0.7 kg-m, 3-5 ft-lb)

STOP RINGS

15-36

FRONT WHEEL/SUSPENSION

Loosen the lower fork pinch bolts and adjust the
fork tube level so that the air joints touch the
underside of the fork top bridge.
Tigh ten the air joint mounting screws.

Tighten the upper and lower fork pinch bolts.
TORQUE :

Upper: 9- 13 N·m (0.9-1.3 kg·m, 7-9 ft·lb)
Lower: 45-55 N·m (4.5-5.5 kg-m, 33- 40 ft-lb)
Install the front fork stabilizer.
Install the removed parts in the reverse order of
removal.
- front fender.
- front wheel.
- brake calipers.
- instruments.
- coupler box.
- headlight case and headlight.
With the f ront brake applied, pump the front forks
up and down several times.
Tighten the front fork stabilizer mounting bolts.
TORQUE : 18-28 N·m (1.8-2.8 kg-m, 13-20 ft-lb)

Install the bolt caps.
Fill the fork tu bes with air to 0-40 kPa (0-0.4
kg/cm 2 , 0-6 psi). and check for leaks.

CAUTION:
Use only a hand operated air pump to fill
the fork tubes. Do not use compressed air.
Maximum pressure is 300 kPa ( 3 kgfcm 2 •
43 psi). Do not exceed this or fork tube
component damage may occur.
With the front brake applied, pump the front
forks up and down several times. Place the motorcycle on its center stand . Check the air pressure
and adjust if necessary.

15-37

FRONT WHEE L/SUSPENSION

STEERING STEM
REMOVAL
Remove the following components.
- coupler box (page 15·3).
- headlight and case (pages 15·4 and 15-5) and
bracket.
- instruments (page 15-6).
- ignition switch (page 15-9).
- handlebars (page 15-11).
- front wheel (page 15-18).
- brake three way joint.

Remove the angle sensor.

ANGLE SENSO R

Loosen the steering stem pinch bolt.

LOCK NUT WRENCH, 30 x 32 mm 077 16-0020400 OR
COM MERCIALL AVAILABLE IN U.S.A.
EXT ENSION BAR

Remove the steering stem nut, fork bridge, front
forks, and fork air jo1nts (page 15-25).

BO LT

15-38

FRONT WHEEL/SUSPENSION
Straighten the lock washer tabs and remove the
lock nut and lock washer.

STEER I NG STEM SOCKET

Loosen the bearing adjustment nut and remove
the steering stem.

07916-3710100

Check the steering stem bearings for damage or
wear.

BEARING REPLACEMENT
NOTE :

Replace the bearing and bearing race as a set.
'83:
Remove the bearing from the steering stem.
After '83:
Remove the bearing inner case and dust seal from
the steering stem.

BEARING

15-39

FRONT WHEEL/SUSPENSION

Remove the upper bearing race with the special
tool.

ATTACHMENT, 42 x 47 mm
07746-0010300

RACE REMOVER ATTACHMENT
07953-MJ1000A (U.S.A. only)

,,.

NOTE:
Use side "A" of the race remover attachment
07953- MJ 1OOOA.

Remove the lower bearing race with the special tool.
NOTE:
If the motorcycle has been involved in an
accident, examine the area around the steering
head for cracks.

ATTACHMENT,
....._
37 x 40 mm
07746-00 10200 .....

Drive the upper bearing outer race into the head
pipe with the special tools.

DR IVER 07749-00 10000

Drive the lower bearing outer race into the heacf
pipe with the special tool.

ATTACHMENT, 42 x 47 mm
07746- 0010300

15-40

BALL RACE DRIVER
07946- 3710701 OR ATTACHMENT,
52 x 55 mm 07746- 0010400

FRONT WHEEL/SUSPENSION

Install a dust seal onto the steering stem and press
the lower bearing inner race over the stem with
the special tool.

~

..........

STEERING STEM DR IVER 07946-MBOOOOO OR
ATTACHMENT "B" COLLAR 07964- MB00200
AND 07946-371

INSTALLATION
Pack the bearing cavities with grease .
'83:
Insert the steering stem into the steering head pipe
and install the bearing retainer and upper bearing
inner race.
After '83:
Install the lower bearing and grease retainer onto
the steering stem, then insert the steering stem into
the steering head. Install the upper bearing and
inner race.

STEERING STEM SOCKET

Install and tighten the bearing adjustment nut:

07916- 3710100

TORQUE:

'83: 14-16 N·m (1.4-1.6 kg.m, 10- 12 ft·lb)
After '83: 19-23 N·m (1.9-2.3 kg-m, 14-17 ft·lb)

15-41

FRONT WHEEL/SUSPENSION

Turn the steering stem lock·to·lock 5 times to seat
the bearings.

STEER ING STEM SOCKET
'83:
Tighten the adjustment nut to the specified torque.
TORQUE: 10- 12 N·m {1.0-1.2 kg·m, 7-9 ft·lb)
Again turn the steering stem lock-to-lock 5 times to
seat the bearings, then tighten the adjustment nut
to the same torque.
After '83:
Tighten the adjustment nut to the specified torque.
TORQUE : 19-21 N·m (1.9-2.1 kg·m, 14-15 ft-lb)

Install a new bearing adjustment nut lock washer
aligning the tabs with the grooves in the nut. Bend
two oposite tabs down into the grooves.
NOTE :
~ckwasher.

jooNOT

install a used bearing adjustment

15-42

07916-3710100

FRONT WHEEL/SUSPENSION

Hand tighten the lock nut.
Hold the adjustment nut and further tighten the
lock nut only enough to align its grooves with the
lock washer tabs.
NOTE:

If the lock nut grooves cannot be easily
aligned with the lock washer tabs, remove the
nut, turn it over and reinstall it.
Bend two lock washer tabs up into the lock nut
grooves.

Install the front forks (page 15·36).
Install the fork top bridge and tighten the stem nut.
TORQUE :
'83, '84, '85:
80-120 N·m (8.0-12.0 kg-m, 58-87 ft-lb)
After '85:
90-120 N·m (9.0-12.0 kg-m, 65-87 ft-lb)

LOCK NUT WRENCH, 30 x 32 mm 07716-0020400
COMMERCIALLY AVAILABLE IN U.S.A.

EXTENSION BAR 07716-0020500
COMMERCIALLY AVAILABLE IN U.S.A.

Tighten the steering stem pinch bolt.

STEERING STEM PINCH BOLT

TORQUE: 18-30 N·m (1.8-3.0 kg·m, 13-22 ft·lb)

15-43

FRONT WHEEL/SUSPENSION
STEERING HEAD BEAR ING PRELOAD
Install the front wheel (page 15·23).
Place a stand under the engine and raise the front
wheel off the ground.
Position the steering stem at the straight ahead
position.
Hook a spring scale to the fork tube and measure
the steering head bearing preload.
NOTE:

Make sure that there is no cable or wire
harness interference.
The preload should be within 1.0-1.6 kg (2.213.53 lb) for right and left turns.
If the readings clo not fall within the limit, lower the
front wheel on the ground and adjust the bearing
adjustment nut.
After establishing the bearing correct preload, install
the removed parts in the reverse order of removal.

15-44

REAR WHEEL/SUSPENSION

30-40 N-m
(3.0-4.0 kg-m,
22-29 ft-lb)

100- 130 N.m
(10.0-13.0 kg-m,
72-94 ft-lb)

16- 20 N-m
(1.6-2.0 kg-m,
12- 14 ft-lb)

90-120 N-m
(9.0-12.0 kg -m,
65-87 ft-lb)

16-0

'83.'84.'85:
85-105 N·m
(8.5-10.5 kg-m,
61-76 ft-lb)
45-70 N -m
(4.5-7 .0 kg·m, 33-51 ft- lb)

After '85:
80- 100 N·m
(8.0-1 0.0 kg-m,
58-72 ft·lb)

16. REAR WHEEL/ SUSPENSION
SERVICE INFORMATION

16-1

TROUBLESHOOTING

16-2

REAR WHEEL

16-3

SHOCK ABSORBER

16-9

SWING ARM

16-14

SERVICE INFORMATION
GENERAL
• The rear wheel uses a tubless tire. For tubeless tire repairs, refer to the TUBELESS Tl RE MANUAL.
• When using the lock nut wrench , use a deflecting beam type torque wrench 14·20 inches long. The lock nut wrench increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually'" appl ied to the lock
nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench when used
with the lock nut wrench. The torque wrench scale reading is given with the actual torque specification.

SPECIFICATIONS
SERVICE LIMIT

STANDARD

0.2 mm (0.01 in)

Radial

-

Axial

-

2.0 mm (0.08 in)

-

0.03 mm (0.001 in)

Axle runout
Rear wheel rim runout

I

I
Wheel bearing play
Shock absorber spring free length

.

2.0 mm (0.08 in)

248 mm (9.76 in)

244 mm (9.6 in)

TORQUE VALUES
Rear ax le nut
Axle pinch bolt
Shock absorber mount bolt/nut

'83, '84, '85:
Af ter '85:
Upper
Lower

Swing arm left pivot bolt
Swing arm right pivot bolt
Swing arm pivot lock nut
Rear brake torque rod
Final gear case attaching nut

85- 105 N·m (8.5- 10.5 kg-m, 61 - 76 ft-lb)
80- 100 N·m (8.0- 10.0 kg-m, 58- 72 ft·l b)
20-30 N·m (2.0- 3.0 kg-m, 14-22 ft-lb)
40-50 N·m (4.0- 6.0 kg-m, 29-36 ft·lb)
30-40 N.m (3.0-4.0 kg-m, 22-29 ft-lb)
90- 120 N-m (9.0-12.0 kg-m, 65-87 ft-lb)
16-20 N-m (1 .6- 2.0 kg·m, 12-14 ft·lb)
100-130 N·m (10.0-13.0 kg-m, 72- 94 ft-lb)
18-25 N.m (1 .8- 2.5 kg-m, 13- 18 ft-lb)
45-70 N-m (4.5- 7.0 kg-m, 33-51 ft-lb)

TOOLS
Special

Common

Shock absorber compressor attachment
Swingarm pivot lock nut wrench
Socket bit, 17 mm
Bearing remover shaft
Remover handle
Remover weight

07967- KC10000
07908- 4690001
07703-0020600
07936- 8890100
07936- 3710100
07936- 3710200

Driver
Attachment, 42 x 47 mm
Pilot, 20 mm
Attachment, 37 x 40 mm
Shock absorber compressor
Attachment, 52 x 55 mm
Bearing remover shaft
Bearing remover head, 20 mm

077 49-0010000
077 46- 0010300
07746-0040500
07746- 0010200
07959- 3290001
077 46-0010400
07746-0050100
077 46- 0050600

or KS-HBA-08-469 (U.S.A. ONLY)
Commercially available in U.S.A.

16-1

REAR WHEEL/SUSPENSION

TROUBLESHOOTING
Oscillation
1. Worn tires
2 . Tire pressure incorrect
3. Faulty tire
4 . Bent rim
5. Loose axle
6. Swingarm bearings worn
7. Loose wheel bearings
Soft suspension
1. Shock fluid leaking
2. Shock absorber worn internally

16-2

Hard suspension
- Bent shock absorber
Suspension noise
1. Shock case binding
2 . Loose fasteners

REAR WHEEL/SUSPENSION

REAR WHEEL
REMOVAL
Place the motorcycle on its center stand and remove
the axle nut.

Loosen the axle pinch bolt and remove the rear
axle.

Move the wheel to the right to separate it from the
final drive gear case.
Remove the rear wheel.

16-3

REAR WHEEL/SUSPENSION
WHEEL RIM RUNOUT
Check the rim for runout by placing the wheel in
a truing stand. Turn the wheel slowly, and read the
runout using a dial indicator.
SERVICE LIMITS:
RADIAL RUNOUT: 2.0 mm (0.08 in)
AXIAL RUNOUT: 2.0 mm (0.08 in)
The wheel cannot be trued and must be replaced
if the above limits are exceeded.

INSPECTION
AXLE
Set the axle in V blocks and read the axle runout
with a dial indicator.
The actual axle runout is 1/2 of total indicator
reading.
SERVICE LIMIT: 0.2 mm (0.01 in)

WHEEL BEARING INSPECTION
Turn the inner race of each bearing with your
finger. The bearings should turn smoothly and
quietly. Also check that the bearing outer race
fits tightly in the hub.
Remove and discard the bearings if the races do
not turn smoothly, quietly, or if they fit loosely in
the hub.
NOTE:

I
I

Replace hub bearings in pairs.

Pack new bearings with grease and install them
into the hub with the special tools.
For bearing replacement, see page 16·6.

16-4

REAR WHEEL/SUSPENSION

DISASSEMBLY
Remove the rear disc bolts and the dies.

Remove the final driven flange mount bolts and lift
the driven flange out of the hub.

Remove the oil seal from the hub.
Inspect the condition of the bearings (page 16-4).
Remove the bearings with the bearing remover shaft
(07746-0050100) and head (07746-0050600).
Remove the distance collar.
The bearing must be replaced with a new one if it
is removed.

16-5

REAR WHEEL/SUSPENSION

ASSEMBLY
NOTE
Us~
lithium-based MULTIPURPOSE grease
with MoS2-additive as follows:
MOL YKOTE BR2-S manufactured by Dow
Corning, U.S.A.
• MULTIPURPOSE M-2 manufactured by
Mitsubishi Oil, Japan
STA-LUBE NLGI #2.
Other lubricants of equivalent quality.
• The wheel uses a tubeless tire. For tubeless
tire repairs, refer to TUBELESS TIRE
MANUAL.

LITHIUM BASED
MULTIPURPOSE
GREASE
(MoS2- additive)

0
Pack all bearing cavities with grease.
Press the distance collar into place from the left
side. Drive the right ball bearing in first, then the
left ball bearing.

CAUTION
Drive the bearings in squarely.
Install the bearings with the sealed end
[acing out, making sure they are fully
seated.

A
07746- 0010400
PILOT, 20 mm 07746-0040500

16-6

ATTACH
T, 42 x 47 mm
07746- 0010300
PILOT, 20 mm 07746-0040500

REAR WHEEL/SUSPENSION

Install a new oil seal into the hub.

Install the final driven flange onto the hub and
tighten the bolts.

FI NAL DR I VEN FLANGE

Install the rear disc and tighten the bolts.

16-7

REAR WHEEL/SUSPENSION

INSTALLATION
Apply MULTIPURPOSE NLGI No. 2 Grease
(MoS2-additive) to the final driven flange splines of
the rear wheel and ring gear.
Engage the rear wheel with the final drive case,
making sure the splines are correctly aligned.

Insert the rear axle through the swing arm, washer,
caliper bracket, side collar, hub, and final drive gear.
Tighten the axle nut.

TORQUE:

'83, '84, '85:
85-105 N·m (8.5-10.5 kg-m, 61-76 ft·lb)
After '85:
80-100 N-m (8.0-10.0 kg·m, 58-72 ft-lb)

AXLE NUT
AXLE PINCH BOLT
Tighten the axle pinch bolt.

TORQUE: 20-30 N·m (2.0-3.0 kg-m, 14-22 ft-lb)

16-8

REAR WHEEL/SUSPENSION

SHOCK ABSORBER
RE MOVA L
Remove the left muffler.

Remove the seat.

UPPER MOUNT
BOLT

Remove the tool box.
Remove the right and left shock absorber upper
mount bolts.
Remove the two bolts attaching the rear cowl and
rear grip.

Remove the rea r cowl attaching screws and remove
the rear cowl and rear grip.

16-9

REAR WHEEL/SUSPENSION

Remove the shock absorber lower mount bolt or
nut and remove the shock absorber.

DISASSEMBLY
Lightly compress the damper upper adjuster and
remove the adjuster stopper ring.
Remove the upper adjuster cover.

STEEL BALLS

Release the shock from the compressor tool.
Remove the damper adjuster, springs, and steel
balls.

DAMPER ADJUSTER

16-10

SPRINGS

REAR WHEEL/SUSPENSION

Install the attachment onto the spring.
ATTACHMENT
Set the shock in the compressor as shown and
compress the spring 30 mm by turning the compressor handle.

07967-KClOOOO

SHOCK ABSORBER
COMPRESSOR

07959- 3290001

Remove the upper retainer through its cutout and
remove the compressor.

SPRING FREE LENGTH
Measure the rear shock absorber spring free length.
SERVICE LIMIT: 244 mm (9.6 in)

16-11

REAR WHEEL/SUSPENSION

ASSEMBLY
Place the spring and spring upper seat on the
damper.
NOTE:

Install the spring with the tightly wound end
facing up.

STOPPER

RING-_,~

WASHER-~

0

~

SPRING~

DAMPER
ADJUSTER
SPRINGS

UPPER SPRING S E A T - Q

Set the shock absorber in the compressor with the
attachment and compress the spring.
Install the upper retainer and remove the compressor and attachment.

ATIACHMENT

07967-KClOOOO

SHOCK ABSORBER
COMPRESSOR

07959-3290001

16-12

REAR WHEEL/SUSPENSION
CUTOUTS
Install the steel balls on their original position.
Install the springs and upper adjuster.
Install the upper adjuster cover, aligning the tabs of
the cover with cutouts in the adjuster.
lightly compress the damper upper adjuster and
install the stopper ring.

INSTALLATION
Install the shock absorber and tighten the lower
mount bolt or nut.
TORQUE: 30-40 N·m (3.0-4.0 kg-m, 22-29 ft·lb)

Install the rear cowl and rear grip.
Install the tool box.
Tighten the upper mount bolt.
TORQUE : 40-50 N·m (4.0-5.0 kg·m, 29-36 ft-lb)
Install the seat.
Install the left muffler.

16-13

REAR WHEEL/SUSPENSION

SWINGARM
REMOVAL
Remove the rear wheel (page 16-3) and the final
drive gear case (page 14·3).
Remove the shock absorbers.
Remove the rear brake torque rod.

TORQUE ROD
SWINGARM PIVOT LOCK NUT WRENCH 07908- 4690001
OR KS- HBA-08-469 (U.S.A. ONLY

~-

Remove the swingarm pivot caps and loosen the
right pivot bolt lock nut.

PIVOT CAP

Remove the right pivot bolt, using a 17 mm socket
bit.
Remove the left pivot bolt and remove the swing·
arm.
Remove the boot from the swingarm.

LOCK NUT
LEFT PIVOT BOLT

SOCKET BIT, 17 mm 07703-00205000R
COMMERCIALLY AVAILABLE IN U.S.A.

16-14

REAR WHEEL/SUSPENSION

PIVOT BEARING REPLACEMENT
Remove the dust seals and bearings from both
sides of the swingarm as follows:
Remove the swingarm bearings using the bearing
97936-8890300, handle, 07936remover,
3710100, and weight, 07936-3710200. Install the
remover and expand it as much as possible behind
the bearing race. Strike the weight lightly several
times to move the race out enough so that the
remover can be expanded completely. Slide the
weight again with enough force to remove the race.

2710200

REMOVER WEIGHT

REMOVER HANDLE

07936-371 01 00

DRIVER

ATTACHMENT,

07749-0010000

37 x 40 mm 07746- 0010200

INSTALLATION
NOTE:
Replace the inner and outer bearing races as
a set. Replace the grease retainer plate whenever it is removed.

Install new grease retainer plates. Drive new outer
bearing races into the swingarm.

\

BEARINGS
Apply grease to the pivot bearings, dust seals, and
pivot bolt tips.
Install the bearings and dust seals.

!.,
RIGHT PIVOT BOLT

DUST SEALS

LEFT PIVOT BOLT

16-15

REAR WHEE L/SUSPENSION
"UP" MARK
Install the swingarm boot with the "UP" mark up.

lntall the swingarm and pivot bolts.
Tighten the left pivot bolt to the specified torque.
TORQUE: 90-120 N-m
(9.0- 12.0 kg·m , 65-87 ft-lb)

T ighten the right pivot bolt to 40 N-m (4.0 kg-m,
29 ft-lb). loosen it and retighten to the specified
torque.
TORQUE: 16-20 N-m (1.6-2.0 kg-m, 12-14 ft-lb)
Move the swingarm up and down several times.
Retighten the right pivot bolt to the specified
torque.

16-16

LEFT PIVOT BOLT

SOCKET BIT, 17 mm 07703-0020500 OR
COMMERCIALLY AVAILABLE IN U.S.A.

REAR WHEEL/SUSPENSION
SWINGARM LOCK NUT WRENCH
07908-4690001 OR KS-HBA-08-469 (U.S.A.

Tighten the lock nut while holding the right pivot
bolt.
TORQUE: 100-130 N·m
(10.0-13.0 kg·m, 72-94 ft-lb)

,..

Connect the rear brake torque rod to the swingarm
and tighten the nut.
TORQUE : 18-25 N·m (1.8-2.5 kg-m, 13-18 ft-lb)
Secure the nut with a new cotter pin.
Install the final gear (page 14·18).
Install the shock absorbers (page 16·13).
Install the rear wheel (page 16·8).

REAR BRAKE TORQUE ROD

16-17

HYDRAULIC BRAKES

'84·
After

I

'

\~

/

'"'~

~-

/'

·

~ ~

"~ - - . ~

1 1
•

..

•

'83:
- 2.5 ft·lb)
2- 3.5 N·m
(0.2-0.35 kg·m, 1·4
After '83

\)

1-2
N·m kg-m, . - 1.4 ft·lb)
(0.
1-0.2
07

; ~ - ~)

~-

"~(.,

~ L-~_ , ~
I

-~

:-._~

"-,

.

•t::i.

»-~

~

I , l"

~ -~ -~ ~

.

11

...

!

~

~

f>

t~

t/
cfJ

$

~
~

v .

l

17-0

.

:'

1

~,; I ("';..C4Jo;. ~
o"l70

o~

~

\ ~ \~
•

0

~

,~

&"'\\

()
'

I

,. \

4-7N: \ \
!O 4- o. 7 kg-m,

2.9-5.1ft·lb)

I

!:,.

,

,

.. "'

30-45 N·m
(3.0-4.5 kg·m,

&

/

/33ftlb)

~

f •··

..

I

./

30-45 N·m
2 2- 33 ft·lb)
(3.0-4.5 kg·m,

/;~@

18
25-35N·m
(2.5-3.5 kg·m\, _25ft·lb)

25-35 N-m
(2.5-3.5 kg·m,
1B-25 ft·lb)

&go}."
ijt-0
~
©~

()

i/IIJ

·, .._

"

~ It ~

Q

~

· ·~ ~

' \

~

"""

17. HYDRAULIC BRAKE
TROUBLESHOOTING
BRAKE FLUID REPLACEMENT/
A IR BLEEDING
BRAKE PAD/D ISC

17- 8
17- 10
17-14
17- 17

FRONT MASTER CYLINDER

17- 1
17-2

SERVICE INFORMATION

BRAKE CALIPERS
REAR MASTER CYLINDER

17- 3
17-5

BRAKE PEDAL SHAFT

SERVICE INFORMATION
GENERAL
•
•
•
•
•

The front and rear brakes can be removed without disconnecting the hydraulic system.
Once the hydraulic systems have been opened, or if the brakes feel spongy. the system must be bled.
Do not allow foreign material to enter the system when filling the reservoirs.
Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result.
Always check brake operation before riding the motorcycle.

SPECIFICATIONS
STANDARD
Front disc thickness

4.8-5.2 mm (0.19-0.20 in)

-

Front disc runout
Front master cylinder I.D.

15.870-15.913 mm (0.6248-0.6265 in)

SERV ICE LIM IT

4.0 mm (0. 16 in)
0.30 mm (0.012 in)
15.93 mm (0.627 in)

Front master piston O.D.

15.827-15.854 mm (0.6231-0.6242 in)

15.8 mm (0.62 in)

Front caliper piston 0.0.

31.948-31.998 mm (1.2578- 1.2598 in)

31.940 mm ( 1.2575 in)

32.030-32.080 mm (1.2610-1.2630 in)

32.09 mm (1.263 in)

Front caliper cylinder I.D.
Rear master cylinder 1.0.

-

14.000-14.043 mm (0.5512-0.5529 in)

14.055 mm (0.5533 in)

Rear master piston 0.0.

13.957- 13.984 mm (0.5495-0.5506 in)

13.945 mm (0.5490 in)

Rear caliper cylinder I.D.

30.230-30.280 mm (1.1902-1.1921 in)

30.29 mm (1. 193 in)

30.148- 30.198 mm (1.1869- 1.1889 in)

30.140 mm (1. 1866 in)

'83-'85:

6.9-7.1 mm (0.272-0.280 in)

6.0 mm (0.24 in)

After '85 :

7.1-7.7 mm (0.280-0.303 in)

6.6 mm (0.26 in)

Rear caliper piston 0.0.
Rear disc thickn~

-

-

Rear disc runout

0.30 mm (0.012 in)

TORQUE VALUES
Brake hose bolt

'83, '84, '85: 25-35 N·m (2.5-3.5 kg-m, 18-25 ft-lb)
After '85: 37-43 N·m (3.7-4.3 kg·m, 27- 31 ft-lb)
30-45 N·m (3.0-4.5 kg-m, 22-33 ft-lb)
Front brake caliper
24-30 N-m (2.4-3.0 kg·m, 17-22 ft-lb)
Rear brake pedal
10-14 N·m (1.0-1.4 kg-m, 7-10 ft-lb)
Master cylinder holder
18-25 N·m (1.8-2.5 kg·m, 13-18 ft-lb)
Rear brake torque rod
'83 2-3.5 N-m (0.2-0.35 kg-m, 1.4- 2.5 ft· lb)
Brake master cylinder cap
After '83: 1-2 N·m (0.1-0.2 kf·m, 0.7-1.4 ft-lb)

TOOL
Special
Snap ring pliers

07914-3230001

17-1

HYDRAULIC BRAKES

TROUBLESHOOTING
Brake lever/pedal soft or spongy

Brakes grab

1. Air bubbles in hydraulic system
2. Low fluid level
3. Hydraulic system leaking

1. Pads contaminated
2. Disc or wheel misaligned
Brake chatter or squeal

Brake lever/ pedal too hard
1. Sticking piston(s)
2 . Clogged hydraulic system
3 . Pads glazed or worn excessively
Brakes drag
1. Hydrau lic system sticking
2 . Sticking piston(s)
3. Incorrect rear brake pedal adjustment

17-2

1.
2.
3.
4.

Pads contaminated
Excessive disc runout
Caliper installed incorrectly
Disc or wheel misaligned

HYDRAULIC BRAKES

BRAKE FLUID REPLACEMENTI
AIR BLEEDING
Check the fluid level with the fluid reservoir parallel
to the ground.

CAUTION:
Install the diaphragm on the reservoir when
operating the brake lever(or pedal). Failure
to do so will allow brake fluid to squirt out
of the reservoir during brake operation.
• A void spilling fluid on painted or plastic
surfaces. Place a rag over the fuel tank
whenever the system is serviced.
LOWER LEVEL
UPPER LEVEL

BRAKE FLUID DRAINING
Connect a bleed hose to the bleeder valve.
Loosen the caliper bleeder valve and pump the
brake lever (or pedal).
Stop operating the lever (or pedal) when no fluid
flows out of the bleeder valve.

A contaminated brake disc or pad reduces
stopping power. Discard contaminated pads
and clean a contaminated disc with a high
quality brake degreasing agent.

BRAKE FLUID FILLING
NOTE
Do not mix different types of brake fluid
since they are not compatible.
Close the bleed valve, fill the reservoir with DOT-4
brake fluid, and install the diaphragm.
To prevent piston overtravel and brake fluid
seepage, keep a 20 mm (3/4 in) spacer between the
handlebar grip and lever when bleeding the front
brake system. Pump up the system pressure with the
lever until there are no air bubbles in the fluid
flowing out of the reservoir small hole and lever
resistance is felt.

17-3

HYDRAULIC BRAKES
AIR BLEEDING
NOTE
Check the flu id level often while bleeding
the brakes to prevent air from being pump·
ed into the system.
Use only DOT 4 brake fluid from a sealed
container.
• Do not mix brake fluid types and never re·
use the contaminated fluid which has been
pumped out during brake bleeding, because
this will impair the efficiency of the brake
system.

..
1}

Squeeze the brake lever (or depress the brake
pedal), open the bleed valve 1/ 2 turn, and then
close the valve.

NOTE
Do not release the brake lever until the
bleed valve has been closed.
2)

Release the brake lever (or pedal) slowly and
wait several seconds after it reaches the end of
its travel.

Repeat steps 1 and 2 until bubbles cease to appear
in the fluid coming out of the bleeder valve.
Fill the fluid reservoir to the upper level mark.
l4' ·
'1

~1

It'll

A contaminated brake disc or pad reduces
stopping power. Discard contaminated pads
and clean a contaminated disc with a high
quality brake degreasing age111.
-

17-4

-~

HYDRAULIC BRAK ES

BRAKE PAD/ DISC

PAD PIN RETAINER
BOLT

CALIPER PIVOT
BOLTS

FRONT PAD REPLACEMENT
NOTE:
Always replace the brake pads in pairs
assure even disc pressure.
Remove the pad pin retainer bolt and caliper bolt.
Remove the calipers.

PAD PINS
Remove the pad pin retainer and pull the pad pins
out of the caliper.
Remove the brake pads. ·

Position the pad spring in the caliper as shown.
Push the caliper pistons in all the way.

PAD SPRING,.

17-5

HYDRAULIC BRAKES
PAD PIN
Install the new pads in the caliper.
Install the pad pins; one pad pin first, then install
the other pin by pushing the pads against the caliper
to depress the pad spring.

PADS
RETAINER
Place the pad pin retainer over the pad pins. Push
the retainer down to secure the pins.

RETAINER CLIP
Check to be sure that the retainer clip is in place
on the caliper bracket.

17-6

HYDRAULIC BRAKES
PAD PIN RETAINER BOLT
Install the calipers over the brake discs so that the
discs are positioned between the pads, making sure
not to damage the pads. Install the caliper pivot
bolts.
Install the caliper bolts.
Install the pad pin retainer bolts.

CALIPER BOLT
PAD PIN RETAINER BOLT

REAR PAD REPLACEMENT
Replace the rear brake pads using the same method
as used for front brake pad replacement.

'83, '84, '85:

After '85:

DISC THICKNESS
Measure the disc thickness with a micrometer.
SERVICE LIMITS:
FRONT: 4.0 mm (0.16 in)
REAR : '83, 84, '85: 6.0 mm (0.24 in)
After '85: 6 .6 mm (0.26 in)

BRAKE DISC WARPAGE
Measure the brake disc warpage on a surface plate
with a feeler gauge.
SERVICE LIMIT: 0.30 mm (0.012 in)

17-7

HYDRAULIC BRAKES

FRONT MASTER CYLINDER

OI L HOSE BO LT

DISASSEMBLY
Drain brake fluid from the hydraulic system.
Remove the brake lever and rear view mirror from
the master cylinder. Disconnect the brake hose.

CAUTION:
A void spilling brake fluid on painted or
plastic surfaces. Place a rag over the fuel tank
whenever the brake system is serviced.
NOTE

When removing the oil hose bolt, cover the
end of the hose to prevent contamination.
Secure the hose to prevent fluid from leaking
out.
Remove the master cylinder.

PISTON BOOT

Remove the piston boot from the master cylinder.

Remove the circlip from the master cylinder body.

SNAP RING PLIERS

07914-3230001

17-8

HYDRAULIC BRAKES
After '84:

'83, '84:
Remove the secondary cup and piston. Then remove
the primary cup and spring.

PISTON

Remove the brake light switch from the master
cylinder body, if necessary.

'Z(~

SECONDARY
CUP

Clean the inside of the master cylinder and reservoir
with brake fluid.

~MARY

I'.~ I)
~

i

SECONDARY
CUP

v

PRIMAY~

CAP

i

~
~
I
~

~

~

~

~
~

INSPECTION
Measure the master cylinder 1.0.
Check the master cylinder for scores, scratches, or
nicks.
SERVICE LIMIT: 15.93 mm (0.627 in)

Measure the master piston O.D.
SERVICE LIMIT: 15.8 mm (0.62 in)
Check the primary and secondary cups for damage
before assembly.

.~

17-9

HYDRAULIC BRA KES
ASSEMBLY
'83, '84 :

After '84 :

CAUTION:

------

Replace the master cylinder piston, cylinder,
and spring as a set.
Assemble the master cylinder. Coat all parts with
clean brake fluid before assembly. Install the spring
and primary cup together.
Dip the piston cup in brake fluid before assembly.

CAUTION:
When installing the cups, do not allow the lips
to tum inside out. Be certain the circlip is
seated firmly in the groove.
Install the piston and clip.
Install the boot.

BRAKE FLUID
BRAKE FLUID

~

PISTON

i

DOT-4

~~:

PISTON

~~ b~ ~

~ ~ FRO N T B R AKE~

6

LIG HT SWITCH

OIL HOSE BOLT
Place the master cylinder on the handlebar and
install the holder and the two mounting bolts.
Align the end of the holder with the punch mark
on the handlebar, and tighten the upper bolt first
then tighten the lower bolt.
TORQUE: 10- 14 N·m (1.0 - 1.4 kg-m , 7- 10 ft-lb)
Install the o il hose with the bolt and its two sealing
washers.
Install the brake lever.
Fill the reservoir to the upper level and bleed the
brake system according to page 17-4.

PUNCH MAR K
BRAKE HOSE

BRAKE CALIPERS

PI VOT BO LT

REMOVAL
Place a clean container under the caliper and d is·
connect the brake hose from the caliper.

CAUT ION:
Avoid spilling brake fluid on painted surfaces.
Remove the caliper bolt and pivot bolt.
Remove the caliper.

CALIPER BOLT

17-10

HYDRAULIC BRAKES

CALIPER BOLT
PAD SPRING

DISASSEMBLY
Remove the
Remove the
Remove the
Remove the

BOOTS

pad pin retainer.
pads and pad spring.
caliper pivot col lar and boots.
pistons from the caliper.

PIVOT COLLAR

If necessary, apply compressed air to the caliper
fluid inlet to get the piston out. Place a shop rag
under the caliper to cushion the piston when it is
expelled. Use the air in short spurts.

Examine the pistons and cylinders for scoring,
scratches, or other damage and replace if necessary.

17-11

HYDRAULIC BRAKES

Push the piston seals in and lift them out and
discard them.
Clean the oil seal grooves wit h brake fluid.

CAUTION:
Be careful not to damage the piston sliding
surfaces.

PISTON INSPECT ION
Check the pistons for scoring, scratches, or other
faults. Measure the piston diameter with a micro·
meter.
SERVICE LIMITS:
FRONT: 31 .940 mm (1 .2575 in)
REAR : 30.140 mm (1 .1866 in)

CY LI NDER INSPE CT ION
Check the caliper cylinder for scoring, scratches, or
other faults. Measure the caliper cylinder bore.
SERVICE LIMITS:
FRONT: 32.09 mm (1.263 in)
REAR : 30.29 mm (1.193 in)

17-12

HYDRAULIC BRAKES
COLLAR
BOOTS

ASSEMBLY
If the piston boots are hardened or deteriorated.
replace them with new ones. The piston seals must
be replaced with new ones whenever they are
removed. Coat the seals with silicone grease or brake
fluid before assembly.
.~

Install the pistons with the dished ends toward the
pads.

A0°o

Install the collar boots and collar making sure that
the boots are seated in the collar and caliper grooves
properly.

~07.

Install the pad spring and pads.

,

v-"'1

PISTON

FRONT

INSTALLATION

01 L SEALS

~

/':.
. :.,;r

v

\

PAD SPRING

COLLAR

CALIPER PIVOT BOLT

Be sure that the retainer clip is in position on the
caliper bracket.
Inspect the condition of the caliper pivot bolt boot.
Apply silicone grease or brake fluid to the caliper
pivot bolt.
Install the caliper assembly over the brake disc so
that the disc is positioned between the pads.

CAUTION :

I Be careful not to damage the pads.

RETAINER
CLIP

•

CALIPER
BRAKE HOSE
BOLT
BOLT
BRAKE HOSE BOLT
-

Install the caliper pivot bolt and caliper bolt.
Connect the brake hose and tighten the brake hose
bolt.
TORQUE:
'83, '84, '85:
25-35 N·m (2.5-3.5 kg-m, 18-25 ft-lb}
After '85:
37-43 N·m (3.7-4.3 kg-m, 27-31 ft-lb)

~.,

-

Fill the brake fluid reservoir and bleed the brake
system (page 17-4} .

RETAINER

PIVOT
BOLT

17-13

HYDRAULIC BRAKES

REAR MASTER CYLINDER

RIGHT FOOT PEG BRACKET

REMOVAL
Remove the right foot peg bracket.

Remove the cotter pin and pull out the joint pin
connecting the master cylinder push rod end and
rear brake pedal sh aft.

COTTER PIN

Place a clean drain pan under the master cylinder
and disconnect the brake hoses from the master
cylinder.

CAUTION:
A void spilling brake fluid on painted or plastic
surfaces to prevent paint damage.
Remove the master cylinder attaching bolts and
remove the master cylinder.

ATTACHING BOLTS

17-14

JOINT PIN

HYDRAULIC BRAKES
DISASSEMBLY

SNAP RING

Remove the rubber cover.
Remove the snap ring with snap ring pliers (079143230001) and remove the push rod from the master
cylinder.

Remove the master p iston, primary cup, and spring.

MASTER CYLINDER BODY

PISTON

It may be necessary to apply a small amount of air
pressure to the fluid outlet to remove the master
piston and primary cup.
Clean all parts with brake fluid.

PRIMARY CUP AND SPRING

PUSH ROD

REAR MASTER CYLINDER I.D.
INSPECTION
Measure the inside diameter of the master cylinder
bore.
SERVICE LIMIT : 14.005 mm (0.5533 in)
Check for scores, scratches, or nicks.

17-15

HYDRAULIC BRAKES
REAR MASTER PISTON 0.0.
INSPECTION
Measure the master piston O.D.
SERVICE LIMIT: 13.945 mm (0.5490 in)
Check the primary cup and secondary cup for
damage before assembly.

MASTER CYLINDER BODY

MASTER PISTON

ASSEMBLY
CAUTION:

----

Replace the master cylinder piston, cylinder,
and spring as a set.
-

-

-~

Assemble the master cylinder.
Coat all parts with clean brake fluid.
Dip the piston cup in DOT-4 brake fluid before
assembly.

CAUTION:
When installing the cups, do not allow the lips
to tum inside out. Be certain the snap ring is
seated firmly in the groove.

--------

Install the primary cup and piston.
PRIMARY CUP AND SPRING
Install the push rod and snap ring.

ASSEMBLY
Install the master cylinder and tighten the attaching
bolt.
Connect the push rod end and brake pedal shaft
with the joint pin. Secure the joint pin with a new
cotter pin.
Connect the brake hoses to the master cylinder and
tighten the brake hose bolt.
TORQUE:

'83, '84, '85:
25-35 N·m (2.5-3.5 kg-m, 18-25 ft·lb)
After '85:
37-43 N·m (3.7-4.3 kg·m, 27-31 ft-lb)
Install the right foot peg bracket.
Fill the brake fluid reservoir and bleed the rear
brake system (page 17 ·4).

17-16

PUSH ROD

HYDRA ULIC BRAKES

BRAKE PEDAL SHAFT

REAR BRAKE PEDAL

REMOVA L
Unhook the brake light switch spring and remove
the rear brake pedal.
Remove the cotter pin and joint pin, and then
disconnect the pedal shaft from the master cylinder
push rod.
Unhook the brake return spring and remove the
rear brake pedal shaft.

JOINT PI N

COTTER PIN

BRAKE LIGHT
SWITCH SPR ING

INSTA LLATION
Apply grease to the brake pedal shaft and install it
in the frame.
Hook the brake return spring correctly.
Connect the pedal shaft to the master cylinder push
rod end and install the joint pin. Secure the joint
pin with a new cotter pin.
Install the brake pedal aligning the punch marks on
the shaft and pedal.
Tighten the brake pedal bolt.
TORQUE : 24-30 N·m (2.4- 3.0 kg·m, 17-22 ft·lb)
Hook the brake light switch spring.

BRAKE LIGHT
SWITCH SPRING

17-17

BATTERY/CHARGING SYSTEM

BATTERY

RED/WHITE

-

-1E~D

1

i

R

~ ~ ~
~A

~
0

I

-=-

I
-

w

~

~ ~ ~~

GREEN

18-0

-

FUSE 30A-

r

BATTERY/CHARG ING SYSTEM

r

-=- 1:

...1
...1

ALTERNATOR

"~

--

~

1\

~

r ~ ~ --~

1-

...___

IC

REGULATOR/RECTIFIER
~

MAIN
SWITCH

VOLTAGE
SENSOR

8 LACK

a:
w
<(
CD

18. BATTERY /CHARGING SYSTEM
SERVICE INFORMATION

18- 1

TROUBLESHOOTING

18- 2

BATTERY

18- 3

CHARGING SYSTEM

18- 4

SERVICE INFORMATION
GENERAL
•
•
•

Battery fluid level should be checked regularly. Fill with distilled water when necessary.
Quick charge a battery, only in an emergency. Slow-charging is preferred.
Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the
battery cables.
. • :11, (111

Do not smoke, and keep flames away from a charging battery. The gas produced by a battery will explode if flames
or sparks are brought near.
•
•

All charging system components can be tested on the motorcycle.
Alternator removal is in Section 9.

SPECIFICATIONS
12V 18AH

Capacity
Battery

Specific gravity
Charging rate

1.8 amperes maximum
1,000 rpm

Alternator Capacity

v_o _ lt _ ag _ e _ r _ eg ~ u _ la _ t _ o _ r ________________________

L __ _

10.2A min. (No load)

5,000 rpm
25A min. (No load)

~ ~~

T
__
ra_n_
si_st_o_ri_
ze_d_n_o_n_·a_d_iu_s_ta_b_le_r_e_gu_l_at_o_r ______________

L __ _

18-1

BATTERY/CHARGING SYST EM

TROUBLESHOOTING
No power- key turned on:
1. Main fuse burned out
2. Dead battery
- Low fluid level
- Low specific gravity
- Charging system failure
3. Disconnected battery cable
4 . Faulty ignition switch

Intermittent power:
1. Loose battery connection
2 . Loose charging system connection
3 . Loose starting system connection
4. Loose connection or short circuit in ignition
system
5. Loose connection or short circuit in lighting
system

Low power- key turned on:
1 . Weak battery
Low fluid level
- Low specific gravity
- Charging system failure
2. Loose battery connection

Charging system failu re:
1. Loose, broken, or shorted wire or connection
2. Faulty voltage regulator/rectifier
3. Faulty alternator

Low power - engine running:
1. Battery undercharged
- Low fluid level
- One or more dead cells
2 . Charging system failure

18-2

BATTERY/CHARGING SYSTEM

BATTERY

BATTERY HOLDER BOLT

GROUND CABLE

REMOVAL
Remove the right side cover.
Remove the battery holder bolt.
Pull the battery out, and disconnect the ground
cable at the battery terminal then disconnect the
positive cable.
Remove the battery .

TESTING SPECIFIC GRAVITY
Test each cell with a hydrometer.
SPECIFIC GRAVITY: 1.270-1.290 (20°C, 68° F)
1.270-1.290

Fully charged

Below 1.260

Undercharged

BATTERY TEMPERATURE VS SPECIFIC GRAVITY

1 31

1 304

NOTES
The battery must be recharged if the specific gravity is below 1.230.
The specific gravity varies with the tempe·
rature as shown in the accompanying table.
Replace the battery if sulfation is evident
or if the space below the cell plates is filled
with sediment.

1 256

1 25
1 24

( ......., _
'1~

1

.lt:l

The battery contains sulfuric acid. A void
comacr with skin, eyes, or clothing.
Allfidote: Flush wirll water and get prompt
medical af/ention.

c o·

s·

F' 32'

41 '

10·

so·

15
59'

2o·

sa·

25·
77·

30·

ae

35 '

gs·

40
104·

EL ECTROLYTE TEMPERATURE

Specthc gravity cnanges by 0 007 for every 10'C.

CHARGING
Remove the battery cell caps.
Fill the battery cells with distilled water to the
upper level line, if necessary.
Connect the charger positive(+) cable to the battery
positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-)terminal.
Charging current: 1.8 amperes max.
Charge the battery until specific gravity is 1.2701.290 at 20°C (68°F).

18-3

BATTERY/CHARGING SYSTEM

Before charging a battery, remove the cap
from each cell.
Keep flames and sparks away from a charging battery.
Turn power ON/OFF at the charger, not
at the battery terminals to prevent sparks.
Discontinue charging if the electrolyte
temperature exceeds 45 °C (I I )°F).

CAUTION:
• Quick-charging should only be done in an
emergency; slow-charging is prefe"ed.
Route the breather tube as shown on the
battery caution label.
After installing the battery, coat the terminals with
clean grease.

CHARGING SYSTEM
CURRENT TEST
NOTE

Be sure the battery IS m good condition
before performing this test.
Warm up the engine.
Remove the frame right side cover.
Disconnect the black wire at the regulator/rectifier
coupler.
Disconnect the headlight.
Disconnect the battery positive cable at the battery
terminal and connect an ammeter between the
battery cable and terminal.
Allow engine to idle.
Increase engine speed slowly.
Charging amperage should be a minimum of 10.2 at
1,000 rpm and should be a minimum of 25 amperes
at 5,000 rpm.
Check the stator (page 184) and then the regulator/
rectifier (page 18·5). if the charging specifications
are not met.

STATOR CONTINUITY TEST
Remove the right side cover.
Disconnect the alternator and regulator/rectifier
coupler.
Check for continuity between the leads, and between the leads and ground.
Replace the stator if there is no continuity between
the leads, or if there is continuity between the leads
and ground.

18-4

BATTERY/CHARGING SYSTEM
VOLTAGE REGULATOR/RECTIFIER
TEST
Remove the right side cover.
Disconnect the regulator /rectifier couplers.
Check for continuity between the leads with an
ohmmeter.
NOTE
The test results shown are for a positive
ground ohmmeter and the opposite results
will be obtained when a negative ground ohm·
meter is used.

NORMAL DIRECTION: CONTINUITY
@ probe

e probe

I

YELLOW

GREEN

II

RED/WHITE

YELLOW

REVERSE DIRECTION: NO CONTINUITY
@ probe
I

II

GREEN
YELLOW

RED/WHITE

z

0

f=

z

u
UJ
a:

Q

tUJ

a:

0

;:

e probe

....J

g

<{

..J

YELLOW

a:

RED/WHITE

z

0
~

0

UJ

(/)

a:
UJ

>

w

w

>-

a:

GREEN

VOLTAGE REGULATOR
PERFORMANCE TEST

BLACK

Connect a voltmeter across the battery.
Check regulator performance with the engine
running. The regulator must divert current to
ground when battery voltage reaches 14.0 - 15.0 V.

IC

18-5

IGNITION SYSTEM

SPARK UNITS

BATTERY
TO
TACHOMETER
IGNITION COILS

IGNITION
SWITCH
OFF

1- 3

-- a >:

-=:!.... w
-- 1 1-

..!!:..<(

2

l
SPARK PLUGS

19-0

2-4

1~

1- 3

SPARK UNITS

PULSE GENERATORS

19. IGNITION SYSTEM
SERVICE INFORMATION

19- 1

TROUBLESHOOTING

19- 2

IGNITION COIL

19-3

TRANSISTORIZED IGNITION SYSTEM

19- 4

SERVICE INFORMATION
GENERAL
•

A TRANSISTOR IZED IGNITION SYSTEM is used and no adjustments can be made.

SPECIFICATIONS
.--NO
Spark plug

1--

Spark plug gap
Ignition t1ming

NGK

Standard

X24EPR· U9

OPR8EA·9

For cold climate Below 5° C (4 1° F)

X22EPR· U9

OPA7EA·9

For extended high speed driving

X27EPR-U9

OP R9EA·9

0.8-0.9 mm (0.031-0.035 in)
At idle 10° BTDC
Full advance 37° BTDC/3,800 rpm

Pulse generator air gap

0.4-0.6 mm (0.016-0.024 in)

19-1

IGNITION SYSTEM

TROUBLESHOOTING
The ignition system has two sub-systems; one for
the No. 1 and No. 3 cylinders and one for the No. 2
and No. 4 cylinders. Determine which sub-system is
faulty, then proceed to the detailed tests below.
Engine cranks but will not start
Engine stop switch OFF
No spark at plugs
Faulty transistorized spark unit
Faulty pulse generator
No spark at plug
Engine stop swtich OFF
Poorly connected, broken, or shorted wires
Between ignition switch and engine stop switch
Between spark unit and engine stop switch
Between spark unit and ignition coil
Between ignition coil and plug
Between spark unit and pulse generator
Faulty ignition coil
Faulty ignition switch
Faulty spark unit
Faulty pulse generator
Engine starts but runs poorly
Ignition primary circuit
Faulty ignition coil
Loose or bare wire
Intermittent short circuit
Secondary circuit
Faulty plug
Faulty high tension wire
Timing advance incorrect
Faulty pulse generator
- Faulty spark unit

19-2

IGNITION SYSTEM

IGNITION COIL

IGNITION COILS

REMOVAL
Remove the side covers and seat.
Make sure the fuel tank is less than half-fu ll. Drain
it, if it is more then half-full. Remove the tank
mounting bolts, life the fuel tank up, and hold it
in place with the tank support rod .
Disconnect the ignition wire leads.
Remove the coils by removing the attaching bolts.

CONTINUITY TEST
Measure the primary coil resistance.

RESISTANCE: 2.8 !2

Measure the secondary coil resistance with the
spark plug caps in place.

RESISTANCE : 21-28 kll

19-3

IGNITION SYSTEM

Remove the spark plug cap resistor retainers and
resistors from the caps.
Measure the secondary coil resistance.
RESISTANCE: 13.6-15.5 kQ

TRANSISTORIZED IGNITION SYSTEM
PULSE GENERATOR TEST
Lift the fuel tank up and hold it in place with the
support rod. Be sure that the tank is less than halffull .
Disconnect the pulse generator coupler and measure
the coil resistance.
RESISTANCE : Approximately 480 S1

Between white/yellow and yellow leads ( 1, 3 cylinders)
Between white/blue and blue leads (2, 4 cylinders)

PULSE GENERATOR REPLACEMENT
Remove the clutch cover (page 7· 11).
Remove the pulse generator mounting bolts, and
pulse generators.
Install new pulse generators.

2-4 CYLINDER PULSE
GENERATOR

19-4

IGNITION SYSTEM

Check the air gap with a feeler gauge.
STANDARD AIR GAP :

0.4--{).6 mm (0.016- 0.024 in)
Install the clutch cover (page 7·24).
Recheck the ignition timing (page 3-8).

SPARK UNIT
If the pulse generators, ignition coils, and wiring
are good, and the ignition timing is not within
specification, replace the spark units with new ones
and recheck the ignition tim1ng.

19-5

ELECTRIC STARTER

STARTER
RELAY SWITCH

STARTER
RELAY SWITCH

STARTER MOTOR

GREEN/RED

DIODE
w

C)

STARTER
BUTTON

z
<(
:::r:
u:::r:

CLUTCH
SWITCH

a:U
w~

8
':"

®

BATTERY

20-0

(I)

SHIFT INDICATOR
GREEN

GREEN
~

':"

<t!::

C)

-

20. ELECTRIC STARTER
SERVICE INFORMATION

20-1

TROUBLESHOOTING

20-1

STARTER MOTOR

20-2

STARTER RELAY SWITCH

20-5

CLUTCH DIODE

20-5

SERVICE INFORMATION
GENERAL
• The starter motor can be removed with the engine in the frame.

SPECIFICATIONS

Starter motor

Brush spring tension
Brush length

STANDARD

SERVICE LIMIT

680-920 g (24.0-32.5 oz)

545 g (19.2 oz)

12.0-13.0 mm (0.47-0.51 in)

6.5 mm (0.26 in)

TROUBLESHOOTING
Starter motor will not turn:
Battery discharged
Faulty ignition switch
Faulty starter switch
Faulty gear change switch
Faulty starter relay switch
- Loose or disconnected wire or cable
- Clutch diode open

Starter motor turns, but engine does not turn:
- Faulty starter clutch .
- Faulty starter motor gears
- Faulty starter motor or idler gear
Starter motor and engine turns, but engine does
not start
- Faulty ignition system
- Engine problems

Starter motor turns engine slowly
- Low specific gravity
- Excessive resistance in circuit
- Binding in starter motor

20-1

ELECTRIC STARTER

STARTER MOTOR

STARTER CABLE

REMOVAL

Willi tile ignition switch OFF, remove the
negative cable at the battery before servicing
the starter motor.
Disconnect the starter motor cable at the motor.
Remove the starter motor mounting bolts, and
the starter motor.

STARTER MOTOR

0 -RING

ARMATURE

BRUSH HOLDER

REAR COVER

SHIMS

CABLE TERMINAL AND BRUSHES

FRONT COVER

20-2

ELECTRIC STARTER
BRUSH INSPECTION
Remove the starter motor case screws.
Inspect the brushes and measure the brush length.
Measure brush spring tension with a spring scale.
SERVICE LIMITS:
Brush length:
Brush spring tension:

6.5 mm (0.26 in)
545 g (19.2 oz)

COMMUTATOR

COMMUTATOR INSPECTION
Remove the starter motor case.
NOTE:
Record the location and number of thrust
washers.
-~

Inspect the commutator bars for discoloration.
Bars d iscolored in pairs indicate grounded armature
coils.
NOTE :
Do not use emery or sand paper on the com·
mutator.

COMMUTATOR BAR PAIRS
CONTINUITY : NORMAL
Check for continu ity between pairs of commutator
bars.
Also, make a resistance check between individual
commutator bars and the armature shaft.
There should be no continuity.

COMMUTATORBARSANDARMATURESHAFT
NO CONTINUITY : NORMAL

20-3

ELECTRIC STARTER

Fl ELD COl L INSPECTION

CABLE TERMINAL-MOTOR CASE
NO CONTINU ITY: NORMAL

Check for continuity from the cable terminal to
the motor case and from the cable terminal to the
brush wire.
Replace the starter motor if the field coil is not
continuous or if it is shorted to the motor case.

-

ASSEMBLY/ INSTALLATION

CABLE TERMINAL-BRUSH WIRE (BLACK)
CONTINUITY: NORMAL
BRUSH HOLDER
NOTCH
PIN

CASE

·Align the case notch with the brush holder pin.

Install the rear cover aligning its slot with the brush
holder pin.

PIN

BRUSH HOLDER

SLOT

Install the starter motor in the reverse order of
removal.

REAR BRACKET

20-4

ELECTRIC STARTER

STARTER RELAY SWITCH

'83, '84, '85:

After '85:

INSPECTION
Depress the starter switch button with the ignition
ON. The coil is normal if the starter relay switch
clicks.
Connect an ohmmeter to the starter relay switch
terminals.
Connect a 12V battery to the switch cable terminals. The switch is normal if there is continuity.

CLUTCH DIODE

CLUTCH DIODE
REMOVAL
Lift the fuel tank up and hold it in place with the
support rod. Be sure the tank is less than half-full.
Remove the clutch diode from the wire harness.

IN ONE DIRECTION: CONTINUITY
IN THE REVERSE DIRECT!ON: NO CONTINUITY

INSPECTION
Check for continuity with an ohmmeter.

20-5

21. SWITCHES
21-1
21-2
21-2
21-3
21-4
21-6
21-6
21-7
21-8

SERVICE INFORMATION
OIL PRESSURE SWITCH
BRAKE LIGHT SWITCH
GEAR CHANGE SWITCH
HANDLEBAR SWITCHES
IGNITION SWITCH
CLUTCH SWITCH
FUEL PUMP
FUEL PUMP RELAY

21-8
TEMPERATURE SENSOR
21-9
2 1- 10
TEMPERATURE GAUGE
TACHOMETER
21 - 10
BRAKE AND TAIL LIGHT SENSOR 21-11
21 - 11
WARNING LAMP CHECK UNIT
21-11
TURN SIGNAL CANCEL SYSTEM
21-11
LOW FUEL WARNING LIGHT
THERMOSTATIC SWITCH

SERVICE INFORMATION
GENERAL
• Some wires have different colored bands around them near the connector. These are connected to other wires which cor·
respond with the band color.
• All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
• The following color codes are used throughout this section and on the wiring diagram.
'83, '84:
B = Black
y
=Yellow
L = Blue
After '84:
=Black
=Yellow
Bu = Blue
81
y

G
A

=G reen
• Red
• White

Br = Brown
0 • Orange
Lb = Light Blue

Lg = Light Green
p = Pink
Gr =Gray

G
R

"' Green
= Red
=White

Br = Brown
0 =Orange
Lb • Light Blue

Lg = Light Green
p
=Pink
Gr =Gray

w

w

•

To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals or connections.
• A continuity teste r is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance involv·
ed, or when check ing for high resistance caused by corroded connections.

m

21-1

SWITCH ES
CONTINUITY: BE LOW
0.3 ± 0.1 kg/cm 2 (4 .3 ± 1.4 psi)

OIL PRESSURE SWITCH
Drain the engine oif..
Disconnect the oil pressure switch lead and remove
the switch.
Check for continuity while applying pressure to the
switch.
·
Replace the switch if necessary.
Apply a liquid sealant to the switch threads before
installing the switch.
Screw the switch into the crankcase and leave two
threads from the bottom. Then tighten it to the
specified torque.
TORQUE: 10- 14 N·m (1.0- 1.4 kg-m, 7-10 ft-lb)
NOTE:
Do not overtighten the switch, or the crankcase may be damaged.

BRAKE LIGHT SWITCH
Check the rear brake light switch for continuity
with the rear brake applied.

Check the front brake light switch for continuity
with the front brake applied.
Replace the switches if necessary.

21-2

O IL PRESSURE SWITCH
REAR BRAKE LIGHT SWITCH

SWITCHES

GEAR CHANGE SWITCH
Lift the fuel tank up and hold it in place with the
support rod. Be sure the tank is less than half-full.
Disconnect the change switch coupler.
Check for continuity between each terminal and
ground in each gear position.

'83, '84:

l~y

lg/R

B/Y

W/l

RIW Br/Y

G/0 GROUND
....L

1 -~

~

N

-

- _o

-4+

- -.~4

-1

-~

-~+·

-~4

0-- ------- ----

o--

2nd

4th

-

--....:r-:.:.:··-'1-

--- ---

--l

Jrd

-1

- -+

0- ---

---

--- .....

81/Y W/Bu RIW

Br/Y

G/0 GROUND

o-- -_-_-_+-_-_-_-1-- -

After '84:
~code

Y

Lg/R

....L

IPosit~
1st

1---N

f-~

2nd
Jrd

o-- -- --- - -- - --o-- -- · --- --- · ··- • -o-- -- --- --o -~
---

~-r+

4th
sth

00

-~+1r

-~

-r

0-~

+-r~

I

o--

o--t--

REMOVAL
Remove the gear change switch cover.

GEAR CHANGE SWITCH

Remove the gear change switch attaching screws,
and the switch.

21-3

SWITCHES
HEADLIGHT
HI- LO SWITCH

'83, '84:

HANDLEBAR SWITCHES

After '84:

The hand lebar cluster switches (lights, turn signals,
horn, etc.) must be replaced as assemblies.

HEADLIGHT
HI-LO SWITCH

Continuity tests for the components of the handlebar cluster switches follow :
Continuity should exist between the color coded
wires in eaf h chart.

HORN
BUTTON

TURN SIGNAL
SWITCH
HORN BUTTON TURN SIGNAL
SWITCH

HEADLIGHT HI - LOW SWITCH '83, '84:
'83, '84:
HI :
MIDDLE {N) :
LO:
After '84:
HI:
MIDDLE {N):
LO :

L/W to L
l/W toW to L
l/W toW

Hl2

Hi

0

-o

Hi

Lo

HL2

Bu/W to Bu
Bu/W to W to Bu
Bu/W toW

Lo

0

Color code

l

L/W

(N)

0

0

Lo

0

w

Color code

w

L

R

o- -o

LEFT

Br/Bu to Lb/W and Gr to 0
Br/Bu to 0/W and Gr to Lb
P to G.

RIGHT

0

Color code

Gr

.()

w

Bu

Bu/W

P1

PR

0

D

PL

o- ~

0

LB

~
LB/W

Br/W

0 /W

After '84:
Turn Signal Switch

w
PUSH
LEFT

0

PUSH
RIGHT
PUSH

,....

Color

Gr

code

21-4

.()
~

'83, '84:
Turn Signal Switch

Gr to 0, Br/W to LB/W
Br/W to LB/W and 0/W
Gr to LB, Br/W to 0/W

HOLD the knob to left or right
PUSH the knob: Lg/W to G

Lo

0

~

OFF

After '84:
LEFT:
RIGHT:

Hi

,....

Hi

(N )

TURN SIGNAL SWITCH
'83, '84:
LEFT:
OFF :
RIGHT:

After '84:
Headlight Hi-Low Switch

Headlight Hi-Low Switch

~

R

l

-o

PR

20

Br/Bu

E

r,v.oN

E

W.OFF

0- 1--o

0

......

0--- -o

Pl

o- ~
,....

......
......

lb

PI

r-o
Lb!W 0/W

o- -o
o- -o
G

p

G

Lg!W

SWITCHES
H O RN BUTTON
' 83, '84:
Horn Button

LG to W/G with button depressed.
NO continuity with button released

I BAT3

Ho

After '84:
Horn Button
HO

E

FREE

I

I

I

I
Color code

LG

I

I

PUSH

0

Color code

Lg

W/G

I W/G

STARTER BUTT ON
'83_, ' 84:
B to Y / R with button pushed in.
B/ R to L/W with out.

'83, '84:

After '84:
ENGIN E STOP SWITCH

Starter Button
IG

ST

FREE

HL1

0

PUSH

0

0

Color code

B

Y/ R

ENGINE STOP SWITCH

HL2

-o

B/R

L/W

HL1

HL2

"

.....,
""

After '84:
Bl to Y/ R with button pushed in.
BI/ R to Bu/W with out.
Starter Button
IG

ST

FREE

""

PUSH

0

'-'

Color code

81

Y/ R

'--

STARTER BUTTON
STARTER BUTTON

~

81/ R

Bu/W

ENGINE STOP SWITCH
'83, ' 84
RUN : B to B/W
OFF : No continuity

After '84:
RUN: Bl to BI/W
OFF: No continuity

Engine Stop Switch

Engine Stop Switch

BAT2

IG

OFF
RUN

RUN
()

-o

OFF
Color code
..._

B/W

IG

0

-o

Bl

BI/W

OFF
Color code

B

BAT2

·-

21-5

SWITCHES

IGNITION SWITCH
Remove the fuel tank and disconnect the ignition
switch coupler.
Check continuity of terminals on the ignition switch
coupler in each switch position.

SWITCH POSITION
'83:
LOCK:
OFF:
ON:
PARK:

No continuity
No continuity
R to B, Br/W to Br-continuity
Br to A-continuity

I\Terminal

PA
Position\
t - - - t-p
0
ON
tOFF

BAT1

Tl1

r-o
0

-

o-

0

TL2

r-o

_1

SWITCH POSITION

I

LOCK
Color
code

IG

Br

After '84:
R

B

Br/W

LOCK: No continuity
OFF:
No continuity
ON:
R to Bl and Bu/0, Br/W to Br-continuity
PARK: Br to A-continuity
..---1\Jerminal PA BAT IG FAN TL1
TL2
Position \

Br

SWITCH POSITION
'84:

~-

LOCK: No continuity
OFF:
No continuity
ON:
R to B, Br/W to Br- continuity
PARK: Br to A-continuity
r-~ ~nal
PA BAT1 IG FAN TL 1
Positioi l \
r- p
0
0

t-o

0 -1-0-

ON

~

p

_2-r<)_

o-kr- t-0

ON
TL2

r..
~

,....
~

OFF
LOCK

0-

-0

Br/W

Br

OFF

Color
code

Br

R

Bl Bu/0 Br/W

Br

r---·

LOCK
Color
code

Br

R

B

L/0

CLUTCH SWITCH

CLUTCH SWITCH
Check continuity of the clutch lever (safety ) switch
with the clutch released and applied.
Replace if necessary.

:l$

CLUTCH APPLIED : CONTINUITY
CLUTCH RELEASES: NO CONTINUITY

21-6

SWITCHES

FUEL PUMP
Remove the seat and side covers.
Turn the ignition switch to "OFF". Disconnect the
fuel pump relay coupler and short the black and
white leads of the harness side coupler with a
jumper wire.

WH ITE

COUP LER

Keep flames or sparks away from the workingarea.
Wipe up the spilled gasoline at once.

BLACK

\
FUE L PUMP RE LAY

Disconnect the fuel tube from the carburetor and
put the end of the tube in the beaker.
Turn the ignition switch to "ON" and drain the
gasoline for 5 seconds into the beaker.
Measure the drained gasoline and multiply it by 12.
Multiplied measurement should be in the specified
fuel pump standard delivery.
STA NDARD DELIVER Y:
6 14 cc (22 oz) ±10 % min.

CAUT ION:
Voltage at the battery terminal should be
above 12.5 V.
• Low battery voltage causes insufficient fuel
pump delivery.

Voltage at the battery terminal should be above
12.5V.
If the fuel pump delivery is below the standard
delivery, check the voltage at the fuel pump
coupler.
Short the black and white lead of the fuel pump
relay coupler and turn the main switch to "ON".
Replace the fuel pump if the voltage is above 12.5V.
Inspect for the loose wire or poor contact if the
voltage is below 12.5V.

VOLT METER

21-7

SWITCH ES

FUEL PUMP RELAY
Remove the fuel pump relay from the mount braket.
Check for a burnt sub-fuse.
Check the relay ·coupler for improper contact and
looseness. Measure the voltage between the relay
black wire and a body ground. The battery voltage
should reqi ster with the ignition switch ON.
Make sure that the fuel pump operates while the
relay coupler black and white wires are shorted and
the ignition switch is ON.
If the pump does not operate, check the fuel pump
coupler for improper contact and the fuel pump
(page 21 -7) .

VOLTMETE R

Check for cotinuity between the ignition control
unit blue wire and fuel pump relay coupler blue
wire. If there is continuity, replace the fuel pump
relay. If there is no continuity, replace the wire
harness.

FUEL PUMP
RELAY

'83, '84, '85:
THERMOSTATIC SWITCH

THERMOSTATIC SWITCH
The cooling fan motor is actuated by the thermosatic switch located in lower the radiator.
If the fan motor does not start, disconnect the
switch coupler from the thermostatic switch and
short coupler terminals together with a jumper wire
as shown.
Turn the ignition switch on.
The cooling fan motor should start running.
If it does not start, check for battery voltage from
the black lead (positive) to black/blue (negative) of
the fan motor coupler.
If there is no voltage, check for a blown or faulty
fuse. loose terminals or connectors, or an open
circuit.
If it starts, inspect the fan thermostatic switch as
follows:

21-8

AFTER '85:
THERMOSTATIC SWITCH

SWITCHES

Suspend the switch in a pan of coolant (50-50
mixture) and check the temperatures at which the
switch opens and closes. Make sure that there is no
switch continuity with room temperature and
gradually raise the coolant temperature. The switch
should have continuity (close) at 98-102°C (2082150F).
NOTE
Keep temperature for 3 minutes before
testing continuity. A sudden change of
temperature will cause error of tempera·
ture reading between the thermometer and
the switch.
Do not let the thermometer or switch
touch the pan a~ it will give a fales reading.
Soak the switch in coolant up to its
threads.

TEMPERATURE SENSOR
Disconnect the green/blue wire from the tempera·
ture sensor.
With the engine cold, use an ohmmeter to measure
resistance between the temperature sensor terminal
and the engine.

Check the temperature of the coolant.

21-9

SWITCHES

Run the engine and measure the change in resistance
of the sensor with the engine at operating temper·
ature.

Temperature

60°C
(140° F)

85°C
(185°F)

Resistance
(Ohms)

104.0

43.9

Replace the sensor if it is out of specifications by
more than 10% at any temperature Iisted.

TEMPERATURE GAUGE
Disconnect the wire from the temperature sensor
and short it to ground .
Turn the ignition switch ON. The temperature
gauge segments should move all the way to the
right.

CAUTION:
Do not leave the temperature sensor wire
grounded for longer than a few seconds or the
temperature gauge will be damaged.

TACHOMETER
TACHOMETER
If the tachometer does not indicate properly, check
and repair the No.1 cylinder ignition system.

SPARK UNIT

If the problem still appears. check continuity
between the yellow wire terminal of the wire
harness tachometer coupler and the yellow wire
terminal of the No. 1 cylinder ignition coil and
repair the circuit if necessary.
If there is continuity, replace the tachometer with
a new one.
PULSE GENERATOR

21-10

SWITCHES

BRAKE AND TAIL LIGHT SENSOR
Turn the ignition switch on.
Check the source voltage at the black/brown lead.
If there is no voltage, check and repair the source
circuit.
If there is voltage, measure the voltage at the
white/yellow (positive) and green/yellow (negative)
wires.
VOLTAGE: 5 V
If there is no voltage, replace the sensor unit.

WARNING LAMP CHECK UNIT

PILOT LAMP CHECK UNIT

The tail/stoplight warning lamp and low fuel
warning lamp should light for a few seconds and
go out when the ignition switch is turned on.
If the light does not operate properly, turn the
ignition switch on.
Check the source voltage at the black/brown lead . If
there is no voltage, check and repair the source
circuit.
If there is voltage, check the warning lamp bulb
and wiring between the unit and warning lamp.
If the bulb and wiring are OK, check the ground
circuit.
If the ground circuit is OK, replace the check unit.
ANGLE SENSOR

TURN SIGNAL CANCEL SYSTEM
'83, '84:
ANGLE SENSOR
Turn the handlebar right and left and check the
angle sensor for wear, damage, or looseness.

21-11

SWITCHES

Remove the angle sensor (page 21 · 11 ).
Measure the resistance between the B/Y and the
G/W leads.
RESISTANCE: 10-19 k ohms
Check the resistance between the W and G/W leads
while turning the sensor arm slowly from the left
to the right. The resistance should increase
smoothly.

1±1
·n

TURN SIGNA L SWITCH
Disconnect the cancel unit coupler.
Turn the turn signal switch to the left position
and connect a jumper wire to the B/Bk and Br/B
leads.
The turn signal switch should return to the neutral
position.
Perform the same test for the right turn position.

SPEED SENSOR
Disconnect the cancel unit coupler,
Check for continuity between the W/Bk and the
G lead terminals at the wire harness coupler whil~
turning the front wheel slowly.
RESISTANCE: 0 ,.. oo Alternately

21-12

SWITCHES
CANCEL UNIT
If the angle sensor, turn signal switch, and speed
sensor are normal , and there is no open or short
circuit, replace the cancel unit with a new one.

CANCEL UNIT

TURN SIGNAL CIRCU IT
SPEEDOMETER

€)

TURN SIGNAL
SWITCH
IGNITION SWITCH
SUB FUSE
TAIL lOA

1I

.------<>'\............,a"'(
....------------= ~

MAIN FUSE 30A

BATTERY

CANCEL
UNIT

POSITION LIGHT

21-13

SWITCHES

TURN SIGNAL CANCEL SYSTEM
After '84:
TURN SIGNAL CIRCUIT
TURN SIGNAL
INDICATORS

Br/W
Br/Bu
IGNITION
SWITCH

TURN SIGNAL SWITCH INSPECTION

TURN SIGNAL SWITCH COUPLER

Remove the coupler box cover (page 15-3).
Disconnect the turn signal switch coupler.
Check for continu ity between the switch terminals
in each position.
RIGHT: Br/Bu to 0/W and Gr to Lb
LEFT: Br/Bu to Lb/W and Gr to 0
HOLD the knob to left or right: P to G
PUSH the knob: Lg/W to G

w

R

PUSH
RIGHT

....,
"

....,
"

PUSH
LEFT

....,
"

Color

Gr

code

21-14

L

P.R

0

-o
Lb

PI

0

P. L
.()

0- - 0
Br/ Bu Lb/W OJW

E

W.ON

E

W.OFF

G

I Lg/W

o- ~
0

-0

G

p

SWITCHES

TURN SIGNAL RELAY INSPECTION
NOTE:

TURN SIGNAL RELAY

The turn signal light does not come on unless
the turn signal switch is in neutral.
Remove the right frame side cover.
Connect a jumper wire between the blue/black wire
of the turn signal relay and ground.
Turn the ignition switch ON.
The turn signal light should come on.

If the light does not come on, check the source
voltage at the gray wire terminal while grounding
the blue/black wire of the turn signal relay coupler.

TURN SIGNAL RELAY

If there is no voltage, replace the turn signal relay.

POSITION LIGHT RELAY INSPECTION
Remove the coupler box cover (page 15-3).
Remove the position light relay.
Check for continuity between A and B terminals.
Connect a fully charged 12V battery to the relay
terminals as shown.
The position light relay is normal if there is no
continuity with the battery connected.

POSITION LIGHT RELAY

21-15

SWITCHES
CONTROL UNI T INSPECTION
Turn the handlebar right and left.
Check the angle sensor support and control unit for
wear, damage, or looseness.

'83, '84. '85:

After '85:

Remove the coupler box cover (page15·3).
Turn the ignition switch ON.

CONTROL UNIT COUPLER

Check the voltage between the blue/black and green
wire terminals of the control unit wire coupler.
VOLTAGE: SV min.
Turn the turn signal switch to the left or right
position.
The voltmeter reading should drop from 8V to 1V.
Push the turn signal switch.
The voltmeter reading should rise from 1V to 8V.

21-16

TURN SIGNAL CANCEL UNIT

G-rtlo]

sutsl_jioo

SWITCHES

LOW FUEL WARNING LIGHT
Place the motorcycle on its center stand.
Turn the ignition switch ON and check that the low
fuel warning light comes on for 1 to 4 seconds. If
the light does not go on, check for a blown fuse or
bulb, loose connection, or open circuit in the wire
harness.
Check that the low fuel warning light comes on
within 60 seconds after the ignition switch has been
turned ON with the amount of fuel in the fuel tank
below 3 liters (0.8 US gal).
NOTE :
The light will not go on immediately after the
ignition switch is turned ON.
If the light does not go on within 60 seconds,
replace the sensor.
Check that the low fuel warning light will not light
when the ignition switch is turned ON with the
amount of fuel in the fuel tank is more than 3 liters
(0.8 US gal).
If the warning light goes on, check for a short
circuit in the wire harness or coupler.
Replace the fuel reserve sensor if no shorts are
found.

21-17

22. WIRING DIAGRAM
'83:

1\ R£ AI\ 1 U'll\l SK:NAL 11Vl2CP(Zl'fll)

_/J)

--...

!-)

STOP

;;;0 TAIL LIGIIT
1 2'1~

JCPlll lw)

'1

.r:.a
lr.,

.---..

G Flf•h." L:W

L

l'S.~

'·H

"1: .,. .

1..
'ff f.

(,f\

88

Cj'!l

......

-•, A I

L flAil

,ln:z

0

I

STOP A TAIL SENSOR

~.

l. fl£.11!\ TURN SIQNAL IZV31CP(Z3'11')

:JI !il
~-r

irt · ~

CHAAG£
TURN SIGNAL
SWITCH
0

'-'I.'LR

t~Of\N
S'o\'

SWITCH t !l NI: StOP
STARTER
S"NITCrl

-Ctf

SWITCH

)

IGNlT I()N C~l.S

SPARK UN TS

1

l

~

SVilTCH

~

eJJ(" :.L.TtPNATO
FU£L RESERVOiR SEPt-s<>ft

PUl S£ GEt.EAA lOR
OfL PRtSSURE $'1\ITCH

v
L·

ll •
1\•

HOfl.~

'A'

Or

ero..n

v~no.

o .. · o~:e

~

LO

LIC'II-

Reel

p

p

Whi.,

Qt

c ••,

Btac•

11 •

..-

Green

l.C •.... • L en

crtfll

SWITC>4

0030Z -MB4A-671 0

22-1

INDICATOR LIGHT CLUSTE.R 12VJWX7

'83:

A TURN SIGNAL
NEUTRAL

INDCATOR~

A : O I L PRESSURE INDICATOR

INDCATOR:~

;~STOP

HIGH BEAM INDICA TO~

AND TAIL INDICATOR

\'

'\FUEL RESERVE WARNING INDICATOR

L TURN SIGNAL INDICATOR? \

r ~ coBt

TACHOMETER LIGHT

t
TEMP METER LIGHT
12V34W

~

W:=;
~;=:

i( ("'tJ:~;= I'='=

(

:-, lr:o
u ~

~·

w·-

~

A, FRONT TURN

'I

~fr=gt3

~
W~:'_

~~

"'-<0:>--Br , . _

E: ~ b·W-«=k~ ; ~L

W

Lc.R

st

1

IGNITION SWITCH

uI An
\

I(~
II-

t--

Tu l A "'Y c. B
al& IBj& at
= t'~f '--'-Llrf11

IqJ~ " J~· ~dl
B

W

SPARE
FUSE2 HEADLIGHT

w

FUSFS FRONT
M(,_!!_A POSITION·
LIGHT. TAIL

~

~;

St~l.

u
G< B

-

\IINl

I

~

BATI Tll

""

10

TLI

PA

OFF
ON

p

lo fo

0~

Hll

,...

1"'-. ~·
FREE :o
fO

•C

PUSH

0

ENGINE STOP
SWITCH TURN SIGNAL SWITCH

51

""

10 ~AT

OFF

fO

RUN

OFF

["-,

w

RI O

IOfO

N

l

A

fO

L

PI
~

- t""'A'
IOro

Hll

HO~N

SWITCH

OIM'I.IER SWITCH

~

Pl
.r. LO
(N)
H1

Lo

IOf<)

II<

~L

A

L.FRONT TURN SIGN'tf'"
12V3213CP(23/8W)

STARTER SWITCH

FA~N

p

l

12V32/3CP(23/8W)

IGNITION SWITCH

~,

·&I.~ ~' 8l,:3,
~r,;t

LA

St»

·HORN
11

R

BAll

FFlE

PUSHc2' '2_

IQJ

FU~

6

<

;

oo

F"us~oER';:K

th

GIL

~Ts:CH

1/ FUSE I

FUSEJ METER

I •*l·er,l

G~fH I9P WHll
: 1L&R

- !--r-

t--

~

lr \ ~A r--1·1~J

IL

L ~b

'rf:i~ j;
SIGN~

~f+

t

~- ~ B~'tlr= t~-'m
~ .'Y

LIGHT~'-1

rv (in~

f---1 . _

~

SPEEDOMETER
12V3 4W

\

I

G

STARTING •
MOTOR
..
_

1

W1)

1

~

MOTO;HERL
MO-=====
SWITCH
THI:.AMO I

~ ':HT
~

~

0
H

~OP

22. WIRING DIAGRAM
TOR

REAR STOP
LIGHT SWITCH

ARE
~
STARTING
ADLIGHT
MO..T.O
, •.A.
TEA
o o
AN SIGNAL·
T REAR BRAKE · HORN
ONT POSITION·
o·y
ETER LIGHT · TAIL
wG

STARTER RELAY

FUSE 30A(MAIN)

,...,

BATTERY
12VI8AH

5

TURN SIGNAL FUEL CUT
RELAY

FAN MOTOR

~THERMO

~'"

~ E'
';:.$u
'l

~

MAIN RELAY
FUELPUMP

R.REAR TURN SIGNAL 12V32CP(23W )

W.'G

2P HI

SMM

B
.L

GL

MIN

Gv

STUB£

WG

l TUB£

lOA

LICENSE LIGHT 12V8W

~

BL

~

~;

0

0

PL. TURN SIGNAL
CHECK UNIT

SILICON RECTIFIER
Y

l

ruet-

FRONT STOP LIGHT
SWifCH

1

.,_~

~

_a.wv

L REAR TURN SIGNAL 12V32CP(23W)

REGULATOR/RECTIFIER

IGNITION COILS
CH

SPARK UNITS
PULSE GENERA TOR
OIL PRESSURE SWITCH

a ........ Black
Y • • • Yellow

L ......... Blue

G ... · ··Green
A·
· • Red
w ...... ·While

Br • • • .. 8row11

0 ......... orange

La .. •.. · L ght blue
L& · · · ·· · L •ght green
p
..... pnk

Gr

····Gray

0030Z-MB4A-6710

22-1

WIRING DIAGRAM
INDICATOR LIGHT CLUSTE.R 12113WX 1

'84:

FUEL CUT

R REAR TURN SIGNAL 12V32CP(23W)

["
~

lP~

I®!•

STOP

lif~,."vT

~

r---J,

1: 1:1
l "' -

G AI;.,' L'w
tp
1.4~

O i ~ l <)f

we

L

1.4~

Bt<l

'

~I

L

r

l

L 'II

L

~

~1 ~ ~

w

GR

~

AEO

.,~

o-~r

rW"

I

r:L

. . .,.

o

SILICON RECTIFIER

~

. ~li

TU~E

(-,.1 0

l""l..::ll]
PL TuFiNsiGNAL

1

II

..

h
IJ

CHECK UNIT

~

STOP&. TAIL SENSOR

....-,..

(
L FRONT TURN SIGN1C'
12113Z/lCP(23/8W)

II

,..,

Wt<l

t

h

,II

CLUTCH SWITCH TURN SIGNAL HORN SWITCH ENQII\jE STOP
SWITCH
STARTER
SWITCH
OIMVER SWITCH
SWITCH
TUR'II SIGNAL CANCEL UNIT

IGNITION SWITCH

Of/
p

22-2

FAll

k)

PUSI

IO to

I(

ST

f":.

IOK>

IG ~AT

I

IGNITION COILS

!"

y

·~

I I

[

L--- ' - SPARK UNIT$

I I

l

··.1
l t "-:

o ~rP

1.'~

L REAR

Iff I ..
_1_

"'!!"'

:o!"a

0

~

vrr

ALTERNATOR

FUEl RESER\IOIR SENSOR

PULSE GENERATOR
OIL PRESSURE SWITCH

['\.. w

L

SIGNAL 12Vl2CP(23W)

REGULATOR/RECTIFIER

w.......

~

T~

' /W

B ··· ··· Biac-

A

I<>

orr

I

'1' ••• ••• 'l'tiOW
L ...... Blue
G........ Green
R • • .. Red

OFF
RUH 16

~

G• 8 '

ENG IN!:. STOP
STARTER SWITCH
SWITCH TURN SIGNAL SWITCH

UTI IC Tl l TLI PA "-..., tol l HI. I

OFF

~-LES'OA

I )

' ·-

OUAL HORN

"'ro:K5 lo

AND

TAIL LIGHT
12Vllt3CP(27/IW)

~

IO to

PI

L

p~

WMI

& • · • .. Bto""

o ........ o.ance
ld""'" · L11n1 otA
L& ... • L1cnt are~

p .. .. .. p,k
Gr •• .... •Grey

HORN SWITCH
DIMMER SWITCH
Pl.

;;.;
~

IO ro1<5
10K>

"'
Lo

INi
HI

HU

lJI

IOto

"'

.. ... u;
FAll

!Ot<>

I>USI

II

I

I

0030Z-MB4 A -671 0

WIRING DIAGRAM
INDICATOR LIGHT CLUSTER 12VJWX7

'84:

A. TURN SIGNAL INDICATOR

OIL PRESSURE INDICATOR
STOP AND TAIL INDICATOR
FUEL RESERVE WARNING INDICATOR
IGNITION SW ITCH
REAR STOP

TACHOMETER LIGHT
12V3.4W

FUSEI SPARE

LIGHT SWITCH

~

FUSEZ HEADLIGHT
FUSEJ METER
o
FUSE4 TURN SIGNAL
FRONT RE
•
FUSES FRONTA:OSBRAKE ·HORN
M
ITION•

TEMP METER LIGHT
12V3W

~I

~"'.

FAN MOTOR

~THERMO

STARTII\
MOTC

T·~" ~
o

0

I

g8'"
"'
1
)1 ~ ~M
f
'""' ""

L.tl

FUSEWJ

lOA~

LIO

R. FRONT TURN SIGNAL
12V3Z/JCP( ZJ/ 8W)

::t l 'f'

l:

12V60/ 55W

c:::J-at
G-c::Jo:Hl
/BCJrLIB

1

'~ ,

l FRONT TURN SIGNAL
12VJZ/ JCP(23/ 8W)

'"'" SOON<c "NCEC

IGNITION SWITCH

""

BATJ I()

TLI TLl PA

OFF
OH

p

22-2

~-CESNM

HORN SWITCH
DIMMER SWITCH

ENGINf. STOP
STARTER SWITCH
SWITCH TURN SIGNAL SWITCH
HLI HLl

""' lo f<>

·,c

ST

POSH

~"'-.

IG ~AT

orr

FIIEE

IO fO lo k)

j l.,

IGNITION COILS

0 k)

RUN

OFF

["\_
11

lo k>

w

R

Jo ~

L

PI

,....

N

L

' )of--

IO

PR

ro

PL
-:;;;;:

HU Lo

""'IO f<>

110 8AT3

Ht " "

FAEI

lo

..

PUS

(Ni

~

~

FO

.

)ATOA

FUSE JOA(MAIN)

ENG
TURN SIGNAL FUEL CUT
RELAY
RELAY

FAN MOTOR

~THERMO

R REAR TURN SIGNAL 12V32CP(23W)
FUEL PUMP

L

~<

~

.y'a

IP NIH

!MM

OIL

:c@

~

THERMO UNIT

~SWITCH

N

OIY
• W'Q

B·IUBE
L·TUBE

LICENSE LIGHT 12V8W

STOP AND TAIL LIGHT
12V3213CP(2718W)

.,

STOP
'ITCH

~

L'TUBE

~ II L ~ ruli

,....A.TO

0

SILICON RECTIFIER

PL TURN SIGNAL
CHECK UNIT

STOP & TAIL SENSOR

L REAR TURN SIGNAL 12V32CP(23W)

IGNITION COILS
PULSE GENERA TOR
OIL PRESSURE SWITCH

a ......... Black

Br

Y ........ Ye :low

0 .. · ... Qranae

L ........ Boue
G ......... Green

Ld ....... ·· Lo&ht blue
L& •· .. · Lo&ht areen

R

P ..

.. Ponk

Or··

Gray

.... Red

w........ whole

.. ·· ·Brown

0030Z -MB4 A-6710

WIRING DIAGRAMA

After ' 84:

Q)I

I ~

9
IATIOI'I

~

I!YILIH

~u.!-

~

~

R FRCI'<! T\11110 SO GliAl.

': ! ~ ! ~ J ~ L

••

.•
,.J..
l.u;-=-. I r-

~ ·

Y
O)

r .. . . ...,

~ -:8o
I

1

~

SlOP AN0 TAIL UGIIT

~$ f

· :~ )
(lilt..I

PII.OT Ull'

~

CI(

I.HT
$TOP AJiO

(IE~
I. FAONT TURN SIGNAl.
IIVU/1(0(!1/U )

~ Q, ft

.,

~:co

o. :J

1!I

1

Oil
I'M:~W(

&!

G
SIGNAl. CANC£L ~IT
sr~U

IATI

OH

II

'*'

TL1

Ill

0

- - -- - - - --SWITCH CCH'IN.IITV - -- - - -- - - - - - --

SwiTCH

HLI

HL2

1G

ST

$01$0R

L ROR 1\IIIN S•GNAL I!VUCI(Uw)

SWIICM

•v
!V ~N

T ~

--------

BLACK
YE.U.OW

Ill.liE
'"" GAEtH

•

IliOn

0

CIIING:

1..11

Ll

UGIIT 111.11£
UGHT GM:lN
PIN!t

GAlli

R

R£0

p

"

WHIT£

G.

('«;;N£ STOP $W1!()4
1
IG 8AT2

orr

0030Z - MB4 - 6800

22-3

After '84:

PI.OT 1.A11P IIVIW• I

REAR STOP UGt
Fl.ISE
I (HtAOUGtiT)

2(foiETER UGHT)
3 CTURH Slr;HAL·STOP·MIJAH)
• (FOSITIOII'·foi£TER UGHT • n:t.,

TEMP t GEAR FOSITION
IHT

~

l

R

~

00At.i40Rt<t:ff(Q:C:.
:

0

iP(W ) ~

ll

(IUI)m m

iP<-)~

(M''I)

~; ; ;~

TURN SIGNAl CANCEL UNIT

- - - - -- - - - - -- - - - - SWITCH OOHTINUITY'--------- ~NE

STARTER SWITCH
S.UI

orr
0~

1G

FAN Tl

RZ

.._, .u

IG

STOP SWITCH

,,

sr

llAT2

orr
lliJN

orr

10R5
PUSH

~ OP

WIRING DIAGRAMA

AEAA STOP lXoHT Slft!CH

~

SIGNAL AElAV

F'VEl. P\.NP

lP(81~ ·

J
IP(B ~ ~

(MINI

W/ G Sw1l!
G.

w

(MINI

81 ., ....

a,.,...

WG

OG

IIIW
UCOiC( UGHT IIVIW

v3:])
58t

r ,_,.
STOP AICI TAll UGH1

"'

~

SIUCON AECTIFIER

.
...

t-!."',..,... •

f'(R}

¥~

(IIIH)

PilOT lAif' CHECK \.NT

L AEAA MN SIGNAL IIVl!<P(IlW)

AE(U.ATOIVAECTnR
SWITCH

•
y

llw

"
ClOWER SWITCH
Hl2

lt

lOiN SWITCH

YEUOW

•

Ill.€

u

GIIDH
11[1)

Lt
p

WitTE

r..

a.ACK

0

--

IA)WN

UGHT 81.1.€
UGHT GRWI

HO 8AT3

Ho

FREE

0030Z - MB4 - 6800

22-3

23. TECHNICAL FEATURES
ONE-WAY CLUTCH SYSTEM

23-1

OPTICAL-FIBER ANTITHEFT DEVICE

23-3

ONE-WAY CLUTCH SYSTEM
First time on a production motorcycle, this system has been proven on the race circuits of Europe in Honda's Gran Prix road
racers.
Rear wheel lock up caused by rapid downshifting and the resulting high engine compression braking force is prevented by the
slippage of the one-way clutch.

ONE-WAY CLUTCH

ONE-WAY
CLUTCH OUTER

CLUTCH OUTER
COMP

CLUTCH
CENTER

• Construction
The one-way clutch is installed with the clutch center' inside the clutch outer. Half the clutch plates are controlled by the
one-way clutch. The one-way clutch allows those plates to slip when backloading force during deceleration might normaly
~
cause the rear wheel to lock-up.
~
Except for the one-way clutch, the primary driven gear/clutch assembly is a conventional design.

23-1

TECHNICAL FEATURES
• Operation

CLUTCH OUTER

During acceleration. cruising, and deceleration,
power is transmitted through the clutch in the
normal manner:
disc~plate
~ neo
- way
clutch
Clutch outer~ficn
~

ONE-WAY
CLUTCH
OUTER

mainshft.

- ~-u

ONE-WAY
CLUTCH
INNER

MAINSHAFT
When there is a backloading on the clutch caused by
the rear wheel nearing lock-up, the one·way clutch
(A) will slip just enough to ·prevent the wheel from
locking: without losing the benefit of maximum
engine compression braking.

ONE.WAY
CLUTCH
INNER

CLUTCH
CENTER

• POWER FLOW DIAGRAM

-ORDINARY POWER FLOW
----BACK LOAD

23-2

CLUTCH
OUTER

TECHNICAL FEATURES

OPTICAL-FIBER ANTITHEFT DEVICE
The device consists of a built-in power source, buzzer, photo transistor light emitting diode (LEO), and fiber scope locking
wire.
Function
Braking the fiber scope causes the buzzer to sound due to interrupted transmission of light from the LED to the photo transistor. A 9V dry battery is used to operate the system. The wire can be connected and disconnected with the ignition key and
is stored in a compartment at the rear of the seat.

PHOTO TRANSISTOR

FIBE R SCOPE

I

LIGHT EMITTING DIODE

23-3

24. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1 . Check fuel flow to carburetor

NOT REACHING CARBURETOR

(1 )

(2)

REACHING CARBURETOR

2.

l

Perform a 3·point spark test

(3)
(4)
(5)

WEAK OR NO SPARK

(1)

(2)

GOOD SPARK

(3)
(4)
(5)

(6)
(7)
(8)

3. Test cylinder compression

LOW COMPRESSION

(1)

(2)

COMPRESSION NORMAL

l

4. Start by following normal procedure

(3)
(4 )
(5)
(6)
(7)

ENGINE STARTS BUT STOPS

( 1)

(2)

ENGINE DOES NOT FIRE

(3)
(4)

j
5.

Remove and inspect spark plug

(5)

WET PLUG

( 1)
.(2)

(3)
(4)

POSSIBLE CAUSE
Fuel tank empty
Clogged fuel tube or fuel filter
Sticking float valve
Faulty fuel pump
Pinched fuel tank vent hose

Faulty spark plugs
Fouled spark plugs
Faulty spark unit
Broken or shorted high tension
wires
Faulty spark unit
Broken or shorted ignition coil
Faulty ignition switch
Faulty pulse generator
Low battery charge
Improper valve clearance (too
small)
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
Improper choke operation
Carburetor incorrectly adjusted
Intake pipe leaking
Improper ignition timing
(Spark unit or pulse generator)
Fuel contaminated

Carburetor flooded
Choke closed
Throttle valve open
Air cleaner dirty

24-1

TROUBLESHOOTING
ENGINE LACKS POWER
1. Raise wheels off ground and spin by hand

WHEELS DO NOT SPIN FREELY

( 1)
(2)

(3)

WHEEL SPINS FREELY

t

2. Check tire pressure

(4)

PRESSURE LOW

POSSIBLE CAUSE
Brake dragging
Worn or damaged wheel bearings
Wheel bearing needs lubrication
Final gear bearing damaged

(1) Punctured tire
(2)

Faulty tire valve

PRESSURE NORMAL

+

3. Accelerate rapidly from low to second

t

ENGINE SPEED INCREASES PROPORTIONALL Y TO ACCELERATION
WHEN CLUTCH IS RELEASED

t

4 . Accelerate lightly

ENGINE SPEED INCREASES BUT MOTOR·___.Itl Clutch slipping
CYCLE DOES NOT ACCLERATE WELL
121 Worn clutch discfplate
(3) Warped clutch disc{plate
WHEN CLUTCH IS RELEASED

ENGINE SPEED DOES NOT INCREASE

(1) Carburetor choke closed
(2)
(4)

1

5. Check ignition timing

Clogged air cleaner

(3) Restricted fuel flow

ENGI NE SPEED INCREASES

Clogged muffler

(5) Pinched fual tank vent hose

INCORRECT

(1)
(2)

Faulty spark unit
Faulty pulse generator

CORRECT

t

6 . Check valve clearance

INCORRECT

(1)
(2)

Improper valve adjustment
Worn valve seat

CORRECT

t

7. Test cylinder compression

TOO LOW

(1)

(2)

(3)

NORMAL

t

8. Check carburetor for clogging

(4)

Valve stuck open
Worn cylinder and piston rings
Leaking head gasket
Improper valve timing

CLOGGED

( 1)

Carburetor not serviced
frequently enough

FOULED OR D ISCOLORED

(1)

Plugs not serviced frequently
enough
Spark plug with incorrect heat
range
Air cleaner dirty

NOT CLOGGED

t

9. Remove spark plug
NOT FOULED OR DISCOLORED

(2)

t
10. •Check oil level and condition

(3)

INCORRECT

(3)

Oil level too high
Oil level too low
Contaminated oil

VALVE TRAIN NOT LUBRICATED
PROPERLY

(1)

Clogged oil passage

OVERHEATING

(1)

CORRECT

t .

11. A emova cylinder head cover and .mspect
lubrication

t

(1)
(2)

(2) Clogged oil control orifice

VALVE TRAIN LUBRICATED
PROPERLY

t

12. Check for engine overheating

(2)
(3)

NOT OVERHEATING

t

13. Accelerate or run at high speed

ENIGNE KNOCKS

(1) Worn piston and cylinder
(2)

ENGINE DOES NOT KNOCK

Wrong type of fuel

(3) Excessive carbon build-up in
(4)

24-2

Excessive carbon build-up
in combustion chamber
Use of poor quality fuel
Clutch slipping

combustion chamber
Ignition timing too advanced
(Faulty spark unit)

TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEEDS
1. Check ignition timing and valve clearance

INCORRECT--------------(1)
(2)

CORRECT

t

INCORET-

2. Check carburetor pilot screw adjustment

-~

POSSIBLE CAUSE
Improper valve clearance
Improper ignition timing
(Faulty spark unit)

See Fuel System Section

CORRECT

t

LEAKING - - - - - - - - - - -- - --

3. Check for leaking intake pipe

(1)
(2)

Deteriorated insulator 0-i'ing
Loose carburetor

NO LEAK

t

WEAK OR INTERMITTENT SPARK - - - - . . . , ( 1 )
(2)
(3)

4. Perform spark test
GOOD SPARK

Faulty or fouled spark plug
Faulty spar k unit
Faulty ignition col i

POO R PERFORMANCE AT HIGH SPEED
1. Check ignition timing and valve clearance
CORRECT

.t

2. 01sconnect fuel tube at carburetor
FUEL FLOWS FREELY

!

3. Remove carburetor and check for
clogged jet

INCORRECT - - - - - - - -- -- - - - (1 l
(2)
(3)

Improper valve clearance
Faulty spark unit
Faulty pulse generator

FUEL FLOW RESTRICTED----- - - -(1)
(2)
(3)
(4)
(5)

Lack of fuel in tank
Clogged fuel line
Clogged fuel tank breather hole
Clogged fuel valve
Faulty fuel pump

C L O G G E D - - - - - - - - -- - - - _ . . Clean

NOT CLOGGED JETS

t

4. Check valve timing

INCORRECT---------- - --

...,Cam sprocket not installed
properly

CORRECT

t

WEAK-- - - - - - - - - - -- -- - - . Faulty spring

5. Check valve spring tension
NOT WEAKENED

POOR HANDLING ______,.
~

tire pressure
Check

1. If steering is heavy - - - - - - - - -- - - -- - - -- - - - - - - - -- - -( 1) Steering top th read nut too tight.
(2) Damaged steering head bearings
(1)

2. If either wheel is wobling-~

(2)

(3)
(4)

(5)
(6)

3. If the motorcycle pulls to one side -

-

-t~

(1)
(2)

(3)
(4)

Excessive wheel bearing play
Bent rim
Improperly installed wheel hub
Swingarm pivot bearing
excessively worn
Bent frame
Swingarm pivot adjusting bolt too
tight
Faulty shock absorber
Front and rear wheels not aligned
Bent front fork
Bent swingarm

24-3

•
•